Spoke to a Sprint returns rep yesterday
I have replaced my Tour once due to a very erratic Trackball and my second is slightly better but not acceptable, not to mention muffled outbound sound and a loose battery door (I can live with door and I am confident that the muffled sound will be corrected with the next OS revision). I called sprint cs and explained that I wasn't sure if I wanted to return the device and revert to my old phone or exchange it. She suggested that I speak with returns. The returns rep encouraged me to try another Tour. He said that there have been many trackball returns and that they are now shipping phones with that problem corrected. He would not guarantee that my new tour would be better but encouraged me to try another.
So, I expect a replacement tonight.