'04 Explorer XLT Sport Heat Whistling

I just purchased a new Explorer and the heat whistles while on the lowest 2 settings. Of course the dealer claims to be deaf and cannot hear the whistle. It is driving me crazy...anyone else have this issue and know the cause? One other question, does anyone else think the blower is REALLY loud on the higher settings?

We'll tackle #2 first: Yes the blower is REALLY LOUD on the high setting, but it sure works great in this Texas heat when you want to cool down in a hurry. My wife, even after 4 years, is still amazed because my exploder cools down out of the driveway while her car never seems to get cold. Consider it a blessing. I usually start out on high if it's really hot, then maintain the temp on low or med.
And #1: It shouldn't whistle. There is probably something obstructing the air flow through one of the vents, the heating/cooling assy, or air is blowing past somewhere it shouldn't. You'll just have to locate the source of the whistle, then either have another technician acknowledge that you have a problem, or fix it yourself. It wouldn't take much of a misalignment of parts to cause air to be blown by where it shouldn't, and whistle. You will most likely have to do some detective work of your own, so you can point to where you think the sound is coming from. Also, if it's under warranty, make sure the service order has the exact same problem, as you stated it, written clearly on the order. They tried pulling this old trick on me. I returned several times for the same thing, and each time they tried to call it something different. I finally had to DICTATE the words to them, so each service order read the same. That way you have a record of multiple visits for the same thing, in case you need to take more action.

You mentioned you just purchased a NEW explorer. Did you test drive it first? Did you notice the whistling then? Did you purchase a different one from the one you test drove? What's the history?

Didnt hear it in the test drive. It is kind of faint, which is the only reason I havent gone ballistic on the dealer yet. So far most of the issues I have I didnt detect on the test drive for various reasons. The other issue I remembered over the weekend is my fuel gage. When I fill up my tank it takes forever to register full, the dealer says this is normal and it can take up to 40 minutes. Does anyone else have this issue?