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I guess the worst one I've had was Mp BW Megatron. I had one with the misassembled hips.
It comes in Trex mode out of the box, and to transform it, you need to ratchet the hip joints downward. Doing this basically shatters the crotch plastic because of the strain on the gears, but there's no way to know you have the issue without actually doing it...
Mines was much worse than what was actually pictured. Literally the entire leg would slide out from the hips on my copy.
I still remember calling Hasbro about the replacement, and them telling me to fuck off since it was an ebay purchase.
I've been enjoying KO products ever since.