Jim (Jinman) and tc35dforme - with apologies, I'm stealing parts of your lists, and giving the main links that, for me, both describe and provide solutions for most of these "problems" with the Class III Boomers. Choreboy, every mechanical device can have problems, and every brand has them. I, like Jim, have never regretted my TC40D purchase.
1. Battery offgasing causing corrosion around battery and cooler. ( Some of us has gone to sealed batteries ala Optima )
Replacing the Battery on TC29D
batter terminal corrosion
2. No-joy joystick breaking at the screw hole for handle. ( New part engineered differently and fixes the problem )
No joy joystick
3. Low-temp running due to flow bypass at common coolant drain line. This problem happens because the Thermostat's "jiggle-pin" gets stuck in the thermostat, and the thermostat can never close. You can fix the thermostat (the cause), or clamp off the bypass hose (a fix that doesn't correct the cause)
Where the TC45D is not deluxe.
4. Coolant leak at fitting adjacent to oil filter ( Requires new part or reinstallation with high grade thread sealant )
A small leak Contains picture of replacement part.
small antifreeze puddle
5. Sticky/sluggish hydro pedals (clean, lube, and cautious operation seem to be the "cure").
HST pedal sticks under load
Follow-up to sticky hydro. pedals
6. Water getting into tilt-wheel mechanism/piston causing failure.
Frozen Tilt Steering on TC40D
7. Starter fuse (7.5 Amp) blowing, replacement is with an 8 Amp circuit breaker.
Blown Starting Circuit Fuse Thread includes part number for replacement circuit breaker.
8. Instrument panel fogging up. Mostly an annoyance, I don't recall any specific fix ever being proposed, other than replacing the insrument panel.
9. HST pedal plate inadequately welded (Jinman's Syndrome)
Where the TC45D is NOT deluxe
TC35D Pedal linkage busted.