It is far more advanced than the Escape, but the driveline is basically what Ford introduced in the Focus RS back in 2016. You're right that the drive modes are new, however. Ford Calibration has done a great job with the hardware, and good tires will also make a huge difference.
I never had problems with my Ford lug nuts, but I made sure they were only ever removed with a breaker bar and installed with a torque wrench. I think excessive ugga duggas are what destroy the beauty cap.
Could actually be really beneficial to get whatever kinks or potential issues that particular car had worked out prior to you getting it. And since the factory warranty doesn't begin until the point of sale, you'll still be covered even though everything has a few thousand miles on it.
Livernois is pretty popular. There's also Cobb, FreekTune, Stratified, and Unleashed Tuning. I used to go with Unleashed Tuning on my Focus ST. I highly doubt any of them have done anything specific to the BS, yet, but I'm sure one or all of them are willing to have a go at custom tuning maps if...
You could probably get to 200hp with a tune. That's what the Fiesta ST in Europe is making with its 1.5L I3. Still won't be exactly "fast" but some more aggressive throttle mapping could make it feel that way. Might run you ~$500 for the tuning device and tune depending whom you go with.
Very odd, that 910S filter is normally put on 2.0L GTDI engines, but the owner's manual does indeed call for that filter on both engines. Not sure where the disconnect is, maybe I can find out.
Did you notice the filter was too close to a coolant hose coming off of the oil cooler housing?
On my old Focus ST (2.0L turbo) I just went to a good exhaust shop and had them replace the resonator with a straight pipe, so I only had a CPE high-flow cat and the stock muffler. That ended up being just the right amount of sound for me, without droning on the highway.
Not positive, but I think the heated steering wheel button ended up there because this HVAC control was initially designed by Ford of Europe for the Kuga, where they usually think in Right Hand Drive.
Edit: The blank button is used for the electric windshield in other markets.
Happy to hear you're enjoying your new Bronco Sport! I'm part of the team that designed the BS and we really enjoy reading your feedback, good and bad.