Yeah, no offense intended but I wouldn't feel like I'm being taken care of in an arrangement like that. It isn't uncommon for early adopters to experience problems with newly released products.
Interaction between the customer, vendor, and manufacturer can help both the vendor and manufacturer get things on track and deliver a quality product in short order when a problem is discovered. In this case, it's likely that there is a problem with "stacked tolerances" between the Ford control arm and the new spring.
That said because the spring manufacturer is providing the replacement part, they have to take into consideration the + or - tolerances of the factory's lower control arm and provide a part that works within those tolerances. Don't get me wrong, it could be a Ford problem but the resolution weighs heavily in the aftermarket spring manufacturer's arena if they are going to sell into this market.
I understand that $$$'s can be wasted in shipping costs going back and forth but that is often the price vendors/manufacturers pay to get a quality product to market. Having a good-natured customer willing to help out in a case like this is a blessing, and the process should take the least painful route for the customer.
I'd want to have a new set of springs in my possession so that I could measure or check the fit as soon as the bad part is removed. It may turn out that the replacement part isn't any better than the first, but if it is the vehicle is back on the road sooner.
I know this sounds a little harsh on my end but I had a problem similar to this with Magnaflow and the problem was 100% their fault. They left me with a cut factory pipe, and an Edge sitting in the air in my garage for a week before they told me they were not going to make it right. This after telling me thanks for discovering the problem and what they would do to make it right. That's a story for a different day but I understand
@hskrs10 position.
Your vehicle sits while someone else decides whether or not new springs are headed your way. No thanks. I'd pull the bad springs off and have a new set of HR or Steeda springs just waiting to replace them.