Due to the dub being Funimation, some of the voice actors are the same as in their previous dubs. For instance, Kasanoda and Tetsuya are Ayame and Shigure from Fruits Basket. Haruhi's father is Ritsu (also a cross dresser, interestingly).
In the dub, Tamaki is Death Scythe. Hikaru is Death the Kid. Mori is Free. Hunny is Medusa. Haruhi is Kim.
In Black Butler Haruhi is Ciel and Eclaire is Ciel's fiancee, Elizabeth, in the original Japanese. In the English dub Honey is Alois and Kyouya is Sebastian...
We all know Kyouya isn't the nicest guy around, but even he doesn't beat the light-catching prowess of VA-mate The Doctor. Honey is kid!Train, Chika is Leon, Haruhi is Saya, Kaoru is Shiki... the list goes on.
Surpassed the Teacher: Hatori Bisco herself is an example of this, given that she used to be tutored to an extent by Hino Matsuri, the author of Vampire Knight, who at the time was a more experienced mangaka (and Vampire Knight being more popular than Ouran to boot), whom Hatori greatly admired and looked up to. Eventually however, Vampire Knight suffered from Seasonal Rot and a steep loss of popularity along with it, while Ouran continued to climb the ladder of most successful shoujos, making it as far as to the top 10 list in Japan and even surpassing shounens such as Bleach (a rare accomplishment for a shoujo). In contrast, Hino Matsuri was told to end her story earlier than she wanted, her decrease in storytelling-quality and popularity not leaving Vampire Knight substainful enough for the LaLa magazine anymore (same one as Ouran was published in). Ouch.
What Could Have Been: Originally, Kyouya's character didn't exist. The reason Hatori created him was because she was told to add seven more pages to the first chapter. Hence, she figured she needed an extra Host Club member.
Apparently, Hatori was originally considering Haruhi and Mori to fall for each other. This idea might be referenced in chapter/episode 7 where Haruhi blushes when Mori first calls her by name, and they spend some alone time where she's willingly carried by him.
Re: Kyouya: where was this said? In my copy it's the other way around, that if she had 40 pages instead of 50 that she would have had to remove him.