Headphone jack too quiet in replacement iPhones

The lock screen button on my original iPhone started sticking, so I took it to the warranty service. They decided to replace it with a new one.
The problem with the new unit was that the headphone jack was too quiet, and the phone was thinner. We verified this by comparing it to two other original 4S units.
For sound, we used the the same track and the same headphones on all phones. You can really hear that my new replacement was at least twice as quiet. And yes, we've made sure all the settings and iOS / app versions are identical.
As for the thickness, we tried my Olloclip on all the phones, and it straight up falls off the replacement unit, while holding firmly on the other ones. Also, made sure there were no screen protectors on either side of the iPhones.
So, there you go, two of the main use cases for me are now impossible - photography and music.
Took it back to the service. They confirmed the faults and replaced the phone again. With a unit with both of the same problems. When confronted again, they now declined, claiming the defects are not there. So on two separate occasions the service first confirmed, and then declined the very same faults.
Has this happened to anyone? How do you go about this? Are the replacements sent by apple supposed to be like that?

FYI, I bought the Griffin AutoPilot in order to hook our 4g nano to our car stereo and I didn't need the included audio cable. However I put it to use with our speakers in our bedroom which are simple ones that don't directly support the iPod. With the cable that came with the speakers we had this problem - couldn't plug in a dock cable and the audio cable at the same time. The audio cable that came with the AutoPilot has a much slimmer connector and it does the trick.

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