Broken Headphone jack

Hello,
Last Monday, I noticed my ipod touch was broken. The headphone jack would no longer work. The songs were playing but no sound come out through the headphones (tried a few headphones I had lying around).
It became obvious to me that it was a hardware issue when I restored the ipod firmware. Besides, when i slightly moved the headphone jack out of its port i could heard sound through one of the channels.
I ordered the replacement box through support's site. However, the ipod returned to normal functioning on the following day, when I upgraded to 1.1.4. However this morning it happened again, and again this afternoon the ipod turned back to normal behaviour.
I will send it back to Apple on Monday however I'm afraid the tech stuff won't be able to reproduce the problem, since it's quite random as I have explained.
What should I do? attach a note inside the ipod box?
Call support even though phone support has expired (past the 90 free days)?
thanks
Ps. I'm in Spain so going to a genius bar is not an option

Just great ¬_¬
They received the iPod today and after just 1 hour they claim "no trouble found" and reshipped it back to me. Now i'm trying to get hold of tech services to let them know (Again) about the random nature of the issue

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