This is actually a great idea, there is very little on the subject other than a lot of manufacturers confusing and hard to find instructions.
No matter what method you use, it always starts with aquiring an RMA number, shipping instructions and shipping address.
1) Contact technical support and explain your problem in detail, along with all the things you've tried and include complete system specs.
2) Tech support may suggest a thing or two you haven't yet tried, exhaust these before proceeding.
3) They will most likely at this point issue you an RMA number along with shipping instructions and address -- these are usually emailed to you.
I've sometimes found that they don't read your explaination careful enough, so I try to keep it as short as possible while still including details on what's already been tried.
Shipping can be a hassle and an added expense that sometimes outwieghts the cost of replacing the item with a new one.
NCIX has a VIP membership that you can buy with money or trade with points you earn in various ways like posting reviews and clicking a link on the weekly newsletter. This VIP membership allows for FREE RMA shipping to NCIX as well as extended coverage for OEM products. If you buy parts for more than just your personal system, it is extremely advantageous to have this membership! I've had to use NCIX's RMA several times, and they have always been very helpful, quickly able to speak to a real person on the phone, quick to reply to emails and tickets, and gladly issue RMA numbers when all else fails.
I purchase a large percentage of my parts from NCIX due to this service, and don't mind paying a little extra for for it -- although NCIX's prices are usually the best anyway.
When packaging up your part for RMA return/shipping, follow the instructions to the letter. Include or do not include everything they want or do not want. Make sure the RMA number is clearly visible on the outside of the package, I usually write it on several sides.
I like to package the product retail box within another larger box with plenty of stuffing inside to eliminate any movement while still allowing some give if the package is knocked hard. I also package the product within it's retail box very carefully, making sure that nothing can move if/when the box is handled. For example, a motherboard and all it's accessories can shift a lot in it's retail packaging, so I will carefully organise the contents in such a way that nothing can move; I'll even add some crumpled newspaper inside to fill any gaps and stop the accessories from shifting. In the end, when you pick up the box and shake it, nothing should move. I then wrap the retail package in packing paper which hides any printing that may be on the box, and allows for any writing on the outside to stand out clearly.
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