So basicaly I got screwed by their hardware once (out of 12 purchases), but I actually started buying more WD's after that because they don't hassle me when I need an RMA even if their tech people disagree with me.
The only reason I buy mostly Seagate is because only WD's Enterprise drives have 5 year warranties.
That's a very good point. While I'd rather not lose data to begin with, RMA procedure is something else to consider. These days I buy almost all my drives online so if it's bad out of the box, I'm generally going to RMA direct to the manufacturer than send it back to the reseller.
I've never actually RMA'd a Seagate drive.
Maxtor makes you run their useless diagnostic program to get a code before you can get past the RMA screen online, though you can always claim the drive is completely dead. But Maxtor shortened their warranty to 1 year at one point and each time one of my drives died I felt like I was playing the lottery- feed the S/N into the website and see if I got lucky and still had some time left to RMA it. Not to mention the fact that as soon as you get it back from RMA, it's only good for 90 days.
WD's RMA online was simple- just state your reason and get your RMA #.
One other thing about WD- I am in San Diego and my RMA return point for WD is in Irvine, about 75 miles north. That means even using UPS Ground the turnaround time was fast. The replacement Raptor drive I got does say "Refurbished to Western Digital specifications" on it.