It was bound to happen. The little crack just below the right side hinge of my Treo 180 split open. This is the side of the earpiece that takes most of the stress when the cover is opened and closed.
It may not be worth sending the phone back for repair, since it will inevitably cost more than the phone is worth. I’m going to look around the web and see if anyone has documented a reasonably sound approach to repair. It will probably involve use of epoxy of some sort.
If I find anything useful, I’ll point it out.