Wow...I would go my dealer with the machine and the above part just as it stands and DEMAND they do something. With the needle hitting that time you may have also sent the machine "out of sync". I have a 8200 (same machine but not as many fancy stitches) and my foot has come off twice during sewing but this is much more than that.
There was someone who had a lemon machine and finally with her persistence her dealer replaced it. Good luck and let us know what happens.