According to Ford's 2024 annual report, in Management's Discussion and Analysis (MD&A), page 60, payments for warranty costs are listed as one of the material cash requirements for the firm. Page 83 of the MD&A lists warranty costs as one of the firm's "critical accounting estimates" for reporting purposes. Page 107 of the annual report indicates that Ford has accrued a little over $14bn for warranty costs.
Now to really dig into this number more, we'd have to look at the notes to the financials to see how the firm prepares that accrual, how often it is updated, and whether it has proven historically accurate.
But it is fair to say that warranty costs are not a rounding error. This is one of many reasons why when people on the internet post stuff to the effect that companies don't argue about warranty coverage, they are mistaken. Ford, to take one example, has about $14bn reasons to argue about warranty coverage.
Finally, before anyone bashes Ford for what appears to be a large number, any meaningful analysis would need to look at its peer automotive firms in size (GM, Toyota, VW Group, etc.), unit sales, revenue, and what is built into those firms' warranty estimates. My point here is not to embarrass anyone on the forum, or to call out Ford as a crappy automaker, but to put some numbers on this idea that automakers don't care about warranty requirements because the figures involved are not material to them. That is not the case - the costs involved are material to the automakers, and so this gives them incentives to make sure that the issue the customer wants fixed is actually one of defective workmanship or parts.