Sorry to hear about all the troubles... I've had my 2215 for over a year now and have had no problems with the grips or the SD or CF card slots. Sounds like you really were working it hard.
I haven't any problem with the headphone jack, and I use mine as a WMA/MP3 player quite a bit -- as well as a CF Radio card as well. I'm hoping to get a pair of the bluetooth stereo headphones to review soon, so I"ll let you know how those work out.
My biggest problems right now are with the 'upgrades' to the Bluetooth services by Microsoft, which seems to disable all the previously working stuff. When I first got the Belkin BT USB adapter for my PC, I was able to Activesync, file transfer and FAX through the BT interface to my Nokia 3650 phone. Since the SP2 upgrade to the PC and upgrades to the BT stack on my 2215, I can't get either of them to talk to each other or to the phone. I just don't have the time to keep playing with it to try to figure out what's going wrong. I know one problem with the PC is MS 're-assigning' the COM port for the BT adapter everytime its unplugged and replaced -- SHEESH!
Other than that, the other bit of a headache is having my 2215 'shared' around the house (most notably with my wife) to play solitare, pocket bubbles, etc. Now, I've got a screen with a couple of small scratches on it. Oh well, I think it's just about time for an 'evolution' and hand-me-down of the 2215
I think I'm going to wait a bit longer to see what HP has up its sleeve. Although they didn't announce anything major @ CES, I have a feeling we're going to see another couple of new devices in the early spring.