I bought a first year expedition back in 97 and it was plagued with annoyances as well (brakes too small, radiator too small, etc) because the truck was so much larger than the explorer, but they re-used parts instead of properly engineering new parts.

I'm sure it's the same story with the 07. Manufacturers just can't (won't) take the time to actually properly engineer something so you end up with stuff like this (and chrome clad wheels that suck, air conditioner that doesn't work at idle in summer, plastic seals that don't fit on the exterior B -pillar, A/C box that leaks under the passenger dash, A/C seats that don't cool, seat motors that squeak, etc).

I should have known better than to buy a first year truck (EL model) but with baby on the way you make the decisions you have to make

Sorry for the rant!