Brakes have been the one consistent item on this car that has been a trouble spot. Rotors seem to warp easily, although that may be due to the way that I drive as well.
Occasional clunk in front end steering, however, it only happens when the temp is above 80 outside. It's harmless so I've never had it fixed, but Ford issued a technical service bulletin about worn sway bar links causing this behavior, so I'm sure that's what it is. Really just a minor nuisance.
Other than that, routine maintenance. The car is on it's second set of tires. I've changed the oil religiously every 5,000 miles with Mobil 1 synthetic and the engine still runs as good today at 125k miles as it did when I got the car.
Transmission still shifts well and is strong, although I drive a lot of highway miles and expect that it will last a little longer.
Interior is still perfect. Have had no problems with electrical components or fit. The blower fan has an occasional rattle, but still works strong.
In my opinion, this car is a victim of Ford's radical styling. It is reliable, strong and seems to be fairly well put together. Critics of the car don't like the oval styling and I think that leads them to overlook the car's good qualities.
The 24v 3.0 v6 Duratec is, in my opinion, one of the most underrated engines that Ford has built recently. It is strong with 200hp, runs very smoothly and seems to be very reliable. The Vulcan engine in the GL is the source of much of the bad reputation for the Taurus. If you stay away from that engine, I think you'll be pleased.
Interior comfort is good and the cabin is nice and spacious. I am tall (6'2") and the car has plenty of headroom and legroom. In addition, the back seat is adequately comfortable (more so than other cars in this class).
The oval "football" control center is admittedly confusing at first, but once you learn it it seems to be well laid out and easy to use.
The automatic climate control feature works well.
The JBL sound system sounds very nice.
Body and paint quality has been excellent. I have no rust spots and the paint still has a high shine to it. Ford definitely has the Japanese models beat in this department.
Overall, this isn't a flashy car, but represents a good, solid sedan. Honestly, I believe if this car had a Japanese nameplate instead of Ford, it would be more highly regarded. With the prices in the used market, it can be a good value.