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Coco, the gay housekeeper (pilot only)
Walt, intern / nephew of boss (4 episodes, season 4)
Claire, the waitress at the coffee shop (pilot only)
Coach, the roommate (pilot, then guest star later)
Seven, 2nd cousin who moved in (5 episodes in 7th season)
Frankie Bennett, a mischievous boy (pilot only)
Leo, title character's best friend (pilot only)
Cousin Pam, distant cousin who moves in with the family (20 episodes, seasons 7-8)
Luke Brower, homeless kid who's taken in by the family (24 episodes, season 7)
Lana Shields, sexy older next door neighbor (13 episodes, season 4)
Jack 'Danny' Baker, a new cast member from Canada (11 episodes, seasons 4-7)
Mark Brendanawicz, a city planner / romantic interest (30 episodes, seasons 1-2)
Robert California, CEO of company (25 episodes, seasons 7-8)
Arnold 'Arnie' Shemp Thomas, overweight, annoying friend. Husband, then ex-husband to a lesbian (20 episodes, seasons 2-5)
Roy, a college aged kid who moves in, later leaves to live with 'sexy ladies' (1 episode, season 8)