I had some very interesting exchanges with Apple Support which I have documented on this blog. The end result, however, was extremely positive despite having to go back and forth shipping my G4 Powerbook. Don’t know if anyone is interested, but here is my saga:
#1 - http://weblog.techdad.net/2006/09/21/stuck-in-a-vicious-apple-support-circle/
#2 - http://weblog.techdad.net/2006/09/22/a-happy-ending-to-the-apple-support-vicious-circle/
#3 - http://weblog.techdad.net/2006/09/28/more-apple-support-madness/
#4 - http://weblog.techdad.net/2006/10/06/apple-care-came-through-with-flying-colors/
#5 - http://weblog.techdad.net/2006/10/17/apple-care-part-4-back-for-more-repairs-als-broken/
#6 - http://weblog.techdad.net/2006/10/24/powerbook-unboxing-part-3/

After all that, then I did some of my own Hardware madness: http://weblog.techdad.net/2006/10/24/installed-the-keyboard-myself/

I still think that AppleCare/Support is a worth-while investment. You just have to be persistant.