Tom,
The new Legacy is sweet as hell. It's a completely different car, nothing remains from the crapboxes of old.
The Mazda 6 is worth a try. Less luxury, more zoomzoom. Actually, you can option the crap out of it and bring up the luxury quite a bit.
The turbo Hyundai Sonata, seriously.
Chevy Malibu, also, seriously.
I can't believe the maintenance you paid in 10 years on that BMW. We have a 10 year old highlander I've had for 5 years, and we have done nothing but replace 1 sensor for 400 bucks, the serpentine belt for under 100, and new tires for 600, and that was well worth it because I love the tires. Oh, also a 4 dollar bottle of liquid tuneup.
My 14 year old crown vic needed less than 3-4000 total maintenance before I sold it in perfect working order.