An update - sent my jb3 (40gb) to Creative, arrived there 10/17.
I noticed last Wednesday (10/26) that the RMA record had been updated, and the serial number on the replacement had "20G" in it. I called Creative and they confirmed that a 20G jb3 was scheduled to be shipped this past Friday.
The matter was escalated to a supervisor, who pulled the shipment, ensured that a 40G drive was installed, and advised me that they would update my shipping to 2-day for their mistake. (I tried to get them to throw in an extra battery, but they didn't bite <g>). They also reissued the warranty, so I get 90 days for labor and one year for parts from today.
There was also no issue because I dropped it - they say the drop shouldn't have caused the problem I was getting.
My new jb3 arrived today - battery is charging as I type.
The entire experience with Creative was handled with great professionalism and courtesy - I wouldn't hesitate to recommend their support area (at least the RMA support) to anyone.
Good Job, Creative! ++T