Rear brake discs binding requiring new discs, callipers & pads.
Dreadful quality fitting of the dealer fit alarm, causing false alarms and other problems.
Seat belt pretensioner replaced.
Courtesy light switch fault.
Bad rattle from the back seat area (still unresolved).
Sales side of dealership was dreadful. Service side has been much better.
Handling is outstanding - embarassing the much hyped Ford Focus.
Group 7 insurance for this performance is hardly believable.
I'm a private owner of a V reg Astra Sport 1.8i 16v and the rattle in the rear area of my car is caused by bad fitting factory fitted glass. There is a tiny section of about 3 inches in one area which I have padded out so when the tail gate shuts it pushes the glass back into the tail gate frame. It's a simple case of poor quality fitting - I've complained but I've had no response whatsoever, so as far as I'm concerned I'm buying another make next time.
The rear binding of the brakes is intermittent. The mechanics admit the problem and my local dealership replaced the rear calipers last year, but they are squealing like crazy again now - mainly on motorways - I think it's as the discs get hot, because they are not releasing, they expand and bite metal to metal. I've never driven a car on a motorway where I have to constantly apply the hand brake to stop the brakes squealing. Are you aware of a fix for this? My local dealership fitted new calipers about 12 months ago, but the problem is now coming back.
Apart from the above (and the fact the car is not rear wheeldrive!), it is a superb motor and a lot of fun.
Update:
I still have the car after 4 years and 33K miles.
The rear brake problems have returned and it will cost me £180 to have the fix done that they should have done the first time.
What should have been a routine cam belt change at 4th service turned into a £300 cam belt, tensioner, rollers & water pump change at only 32K miles. Again, by all accounts a common problem, but one which the customer is left to pick up the bill for.
The alarm finally went totally haywire last year so I just removed it.
At the 3rd service the dealers wanted to replace the exhaust back box (for >£100) due to a tiny hole in it. The alternate 10p repair with exhaust putty is still holding firm 14 months and another MOT later.