de8212,
My old 2404WBR was only up for about 3-4 months before it died.
The RMA process was pretty painful, mainly because I had to talk to the tech support guy for almost an hour. It was very frustrating, because this guy had a VERY thick Indian accent and spoke very fast, I couldn't hardly understand a word he said. I didn't understand maybe 90-95% of the conversation. Anyway, at the end of the call, he finally gave me 2 numbers - a Case # and an approval # or something like that. I called Customer Support to get the RMA and was put on hold, at which time the voice said that they could now take RMA's online. So I decided to hang up and try their online RMA request system. That was pretty painless, I got the new router in about a week (I did the Advanced Replacement where I get the new one first, then send back my old one within 30-days).
They make you cover shipping your defective unit back to them, however.
I have only had the new unit for 2-weeks.
I leave it on 24/7.