Which drive was it?
I had that happen to me before. I RMA it. It's just easier sometimes to do that.
I am sure your right and lots of RMA are because of this. return data is skewed by the ease in which a consumer can create and RMA and process it.
Some companies let you set up RMA online yourself without talking to anyone. Those companies have the highest return rates.
Companies that make you call in- or troubleshoot first- Obviously have the lowest RMA. Spend on tech support and you save on return costs... Seems logical to me.
Glad you got it back working. Was the data still on it ?