Not sure if this has been posted here, I couldn't find it. It is however listed as a problem with GSM Treo Pros on other sites, but I haven't seen anything listed for the CDMA model.
I looked at my wife's Pro today and noticed that there were cracks along the edges of the front housing on both sides. One was between the volume and camera button, the other was on the side by where the end call button is. This is an apparent manufacturing defect, so lets make Sprint aware of it! I'll be taking ours in tomorrow and see what they are willing to do about it and I'll post back.
She has a phone pocket in her purse, and it's never been dropped. It even has less scratches on it than I've seen compared to other Treo Pros after only a month of use. She takes care of it very well. We've had it exactly 2 months now.
Look at your Treos and see if there are cracks present. They are very thin, and are easy to miss till they get bigger. I will post pictures tonight.
If you can, post photos showing any cracks you've found in your housing so we all can use it as ammo to get these things fixed. Also let us know how long you've owned your Pro, and if possible the manufacture date. I don't have it available on ours right now because my wife had to take off right as soon as I noticed them.
EDIT 7/1/09: Just came from Sprint repair store, and apparently the techs there don't know the difference between "Physical Damage" and "Defective Materials". They of course told me that they hadn't been handed the issue from Palm for replacement on this. So of course, I called Palm. Was on the phone 20 minutes in total and had a service ticket started. I first told the woman on the phone about the cracks by the end call button, then she asked if there was a crack on the opposite side by the volume button too! HOW DID SHE KNOW THAT? LOL Palm knows this is an issue! They offered to have me ship the handset back for FREE repair, or told me I could go back to Sprint with the PALM Service ticket number and have them call to verify that they have approved for repair or replacement! If you find cracks in yours, you'd be better off to call Palm first! I will post an update when I get done taking my new ammo to the Sprint store in the morning.
EDIT 7/15/09: Finally got around to calling Sprint Advanced Exchange today and guess what... sending a new device. Why was this so hard to get done at the Sprint store? Even armed with the Palm service ticket number, they were still calling it damage. This particular "Sprint Tech Store" employs only idiots that have no clue what the difference is between DAMAGE, and DEFECT. +1 to calling in to Sprint as opposed to going in to a Sprint store... they aren't in a rush to help with LEGIT issues. To those that live in Indianapolis, stay away from 39.645315, -86.133596.
You'll get no help there!