rather than rehash the early death discussion, I'll just quote odditory who summarized everything fairly well:
First thing that comes to mind when I see a DOA report is to ask how the drive was packaged, if there was any evidence that UPS dropkicked the package, etc. Even if there's no visible packaging damage, if the drive isn't packaged in retail form (or packaged as recommended by the manufacturers themselves) then that's where I assume the issue originated.
I'm saying I'm giving WD benefit of the doubt that its not manufacturing errors (remember every drive is fully tested when its born) -- its statistically unlikely based on the percentage of drives these guys received that were bad. Newegg is the common denominator here and they have a longtime tradition of not being able to break up the 20-packs from the factory, repackage them into individual shipments and actually get them into customers' hands trouble-free with any consistency. More perplexing is enough people receive bare drives that *do* look adequately packed yet then are knocking/clicking or grinding with crashed heads as soon as power is applied, to make you really wonder WTF? Broom hockey in the warehouse? Robotic pickers not calibrated properly for delicate items? FWIW, this seems to happen much, much less on the retail boxed drives suspended by clamshell brackets.
And you're absolutely right about drives dying a delayed death being often rooted in earlier stresses. That's why you do the several weeks of burn-in and disk thrashing within the 30-day return window because it'll tend to reveal the weaker drives prone to earlier failure. Its been extremely rare that I have a drive survive that burn-in but then fail say 6 months down the line.
First thing that comes to mind when I see a DOA report is to ask how the drive was packaged, if there was any evidence that UPS dropkicked the package, etc. Even if there's no visible packaging damage, if the drive isn't packaged in retail form (or packaged as recommended by the manufacturers themselves) then that's where I assume the issue originated.