Explorer:
- Column shifter gets floppy over time. Easy fix, but a pain to do.
- Plastic shims on door latches have a tendency to break off over time, and doors will not fully close unless you slam them shut
- Sunroof weatherstripping is particularly vulnerable to leaking
- Ride can be a little rough with leafs in the back.
Pajero:
- 150 hp/175 lb-ft doesn't exactly suffice to move a 4,600 brick, even with a 4.56 rear axle ratio.
- The inclinometer is filled with glycerol and has the tendency to leak over time.
- Turning radius is too big compared to the Envoy, Explorer and even the fullsized Expedition
Grand Marquis:
- The '99-'02 40/20/40 factory cloth Town Car seats are not as comfortable as '92-'98 or '03-'12.
- With hot coolant flowing in and out of the heater core in summer, it negatively affects the AC.
- Same issue as the Explorer with the plastic shims on the door latches, exact same part.
- Column shifter gets floppy over time, as with the Explorer.
- Power adjustable pedals used a plastic gear that breaks over time. Guys over at the Marauder forum fabricated one out of brass, which now works perfect.
- Suspension needed a lot of work - Bilstein shocks, EATON Detroit springs, bigger Eibach swaybars, aircraft grade aluminum rear control arms/Watts link amongst a few other improvements - to get it how I like it.
Expedition:
- The 4.6L 2V feels a bit gutless in comparison to an available at the time 5.4L 3V
- The IRS may offer better handling, but isn't as sturdy as the solid rear axle on the Explorer, Envoy and Pajero.
- The 60/40 bench seat isn't as comfortable as it could be.
Envoy:
Primarily typical GM build quality from the 2000s.
- Front lower seat foam starts falling apart over time, causing the plastic trim on the side of the seat to snap. If you replace the seat foam on time, you'll save the trim.
- Quality of plastic used for the door panels is flimsy at best, especially the upper parts.
- Quality of plastic used for the center armrest was so bad, it actually collapsed. Got a replacement made for a Buick Rainier with fake leather/vinyl trim that did the trick.
- The plastic used for the center console is too flimsy - the points where it attaches to the body right under the dashboard snapped right off when I leaned on the right rear part of the center armrest. Took the new one to an upholsterer to "modify" so it doesn't happen again.
- Plastic glove box release handle broke off last year and had to be replaced.
I'll have to post about the Jaguar and the Cadillac later.