In the first three weeks of ownership, I've noticed three minor paint problems. There was a rather visible dirt speck in the paint on the body just below/behind the driver's-side C-pillar that was warrantied, taking about $700 out of Ford's profit on the car. There are two smaller paint flaws; one that shows touch-up paint on the driver's door inside the B-pillar area, and a wee bit of fiber stuck in the painted dash applique below the CD player slot. I'll live with those.
There's a bit of fiber fluff of some sort inside the right headlight shell between the reflector and the outer clear cover. I guess either the Wayne plant or the supplier's factory could use a good vacuuming!
The SYNC system has one glitch; the shuffle function only seems to put only about 12-15 songs into a flat file (same linear order as in my iPod's playlists) queue, which then gets played over and over instead of shuffling all the songs by an artist, or in a playlist or genre, whatever I've asked the system to shuffle. I have to ask SYNC to play the artist/playlist/genre again to get a new batch of 12-15 songs to come up. Dang Microsoft!
Zero mechanical or electrical problems!