I've got a '96 Mercury Mystique that Ford used the wrong insulation on all the engine wiring harnesses - after a few years, the insulation literally turns to dust, and the harness is bare wires all over the place. They came out with a campaign that went to 100k miles to replace the harnesses, but they didn't notify the owners (it wasn't a true recall so they didn't *have* to). Mine's over 100k, and they won't budge on the limit.
I think we as a society have painted ourselves into a corner with our demands on car manufacturers. We want light weight, air conditioners that last over the expected life of the vehicle without requiring a $1000 repair, good fuel mileage, all kinds of so-called safety features (some are actually useful, some not) that work over the life of the vehicle without requiring astronomically costed repairs (ABS brakes, a.c. evaporators, etc.), 0-60 in 6 seconds or less, low pollution (tons of delicate technical gadgest all over the vehilce), able to accommodate every home appliance and gadget you can think of, everything extremely tightly integrated yet easy to work on, low initial cost, low maintenance cost over a 200k mile span, plastics that last longer than plastics can last, and with nothing that breaks after 6 years that costs more than half the value or the car at that point (a.c. evaps and ABS brakes). Plus the union agreements won't allow making existing production more efficient if it eliminates a worker from the line (specifically GM).
I submit that it would be impossible to meet all but 3 or 4 of those requirements in any given car. Between our own personal expectaions and government requirements, we've quaranteed ourselves that we will be unhappy with our cars and the manufacturers - too many compromises have to be made to mee them all - something has to give - and we pay for it.
Bill Putney (To reply by e-mail, replace the last letter of the alphabet in my address with the letter 'x')