>Left side driver's seat plastic panel broke (217 lb. ass to blame?)
Hasn't happened on my 98ML yet, maybe my ass is not heavy enought.
>Battery failed abruptly
happened to me after 2 years of ownership
>CD changer errors intermittently (no resolution)
happens to me now and then, it also get stuck and I couldn't take out the magazine. I suspect the mechanism is dirty and needs some cleansing.
>Catalytic converter leak
>Cracked windshield washer resevoir
>ABS/ESP lights came on for no apparent reason (no resolution)
hasn't happend yet.
>Brake pads last 24k miles
dealer changed mine at 22.5k miles while my battery went south, I asked for the inspection of old parts and found that there was still significant pad life left (at that time, I didn't know much, it was probably a dealer rip off). My second set of pads last approx. 30k when I changed them out myself, I think they could last 40k based on our driving habit. I concur with the other user that the Mintex pads are so much better in terms of less dusty and it is just as quiet and performed as well as the OEM pads.
>Tail light bulb burned out prior to 1 year ownership
it can happen to any manufacturers, afterall, the filament inside the bulb is pretty fragile.
>Rear hatch lock failed
my broke after 45k miles, it is a poor design in my opinion, the mechanism could use a better part (i.e. metal) instead of plastic.
>Driver's window glass rattles in frame when partially down
happened to mine too, it seems lots of cars have this rattle problem when window is partially open, Nissans are notorious on this. Too bad they don't make windows ride on a track, like some older German cars.
>Engine stumbled and quit after starting for no apparent reason (no resolution)
it is the security ring on the ignition, mine got replaced 3 times before it finally behaves properly.
>Still waiting for that harmonic balancer to let go.
I had the dealer changed it. cost $370 parts and labor. I have the old part and it ain't too bad after 53k miles of service.

I feel for your pain, lot of ML owners went through it. I think that my ML now is running better and more reliable than it was 5 years ago and I am going to keep it for at least 5 more years.

steve