Replacement Nano under warranty also defective. Will not pay shipping 2x!!

I had a Nano 2nd Gen purchased last December. It had an audio jack problem and needed to be replaced. I do not have Apple Care, btw. I had to pay shipping to get the Nano replaced; about $30, a shipping fee that is a bit ridiculous in and of itself.
The replacement Nano is defective OUT OF THE BOX. It constantly exhibits playback artifacts (chirping sounds) on podcasts and eventually just stops playing the files altogether. I'm an audio engineer by trade, and a pc geek, so I'm pretty clear on this being defective. I've done the restore, tried different files, different bitrates, blah blah blah. It's defective, period.
The real problem is that Apple simply has the automated service requestor page, and I'm again instructed that I will have to pay shipping to get this REPLACEMENT! Nano serviced. Again, this came to me defective right out of the box.
There's no way I should have to pay shipping to get a replacement of a replacement. In other words, for a Nano that cost about $149 new, I'm going to have to end up paying $60 under warranty to get something that works?
What are my options here? Other people must have had this happen to them. I would appreciate some help. Is there any other way to get Apple to waive the replacement of a replacement shipping fee?
I don't want to go ahead with the request for service until I know I can get it fixed/replaced free of charge this time.
If I have to pay again to get a replacement for something that was sent defective, I will just throw the thing in a drawer, and Apple will have lost a customer for life.
Ipod Nano 2G 2nd Generation Windows XP Pro
Windows XP Pro

Doesn't matter what carrier you go to if it happens again then you'd be in the same place. Carriers are only the middlemen so that you don't have to wait long for device replacements and the guidelines are set by the manufacturer is what is and isn't covered. Your best bet is to pressure Samsung if you believe it's a manufacturer defect.

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http://www.ifixyouri.com/16-ipad-repairs
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