
The green dot means you'll live to call another day. Non-green dot, not so much. (click to embiggen)
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Last month Apple issued a voluntary recall of its Ultracompact USB Power Adapter for the iPhone 3G. The UUPAFTi3's metal prongs were prone to break off and increased the risk of electric shock, fire and iPhone 3G withdrawal from the inability to keep it charged. Users could either drop by the local Apple Store and pick up a new adapter beginning October 10, or order a replacement via the web.

The new adapter in it's oversize box and enough padding for a Fabergé Egg. (click to embiggen)
Reviews editor, Ray Aguilera opted to have his new shock/fire-free adapter be shipped to him. What arrived was a box about 5 times too big and a warning from Apple:
If you do not arrange collection of the return envelope/box within 10 business days of the date on which you receive this letter, Apple will have the right to charge your credit card a non-return fee in the amount described at the time of order confirmation, as you agreed when you requested a repair from AppleCare Service.
This is standard practice, Apple needs to make sure you're not ripping them off like that iPod Mechanic a while back. We're guessing Apple doesn't want anyone burning down their neighborhood with an adapter they've replaced. Still, does the shipping box need that much padding and to be that large?
So what will Apple do with all the old adapters they recieve? Share your guesses in the comments below.
Put a green sticker on them
Submitted by donbullockjr on Mon, 2008-10-06 18:05
Apple will probably put a green sticker on returned adapters. Just kidding. Maybe the defective part can be popped out and replaced with the new and improved power supply. Apple is really good about reusing the boxes. When I was a tech, I was impressed with their shipment of parts in sturdy boxes and a requirement that the used part be returned in the same package. The boxes are sturdy and can be used multiple times. Apple is really good about keeping it green. Plus, it makes good cost sense.
What about the USB cable??
Submitted by kavok on Mon, 2008-10-06 18:15
I just had one melt down on me today. The plastic casing for the dock connector got really hot and made a nice hole through to the metal. Singed my fingers trying to pry it off of the iPhone before it did any damage to it. The cable wasn't plugged into the wall either. It was plugged into a USB port on the Dell computer I was using at the time.
Apple is sending a replacement cable, but I find it odd that they did not want the old one back to see what caused the issue.
I hope the new one doesn't have the same problem.
Box size
Submitted by 3DSteve on Tue, 2008-10-07 08:06
I agree with the above; it is probably a standard box size that Apple uses. No sense ordering a new box, which might have little use beyond this recall. It makes sense financially and environmentally, especially if they can reuse the box for more outgoing shipments.
3G USB Power Adapter
Submitted by IT Certification on Mon, 2009-02-16 04:52
Very nice method to replace iPhone 3G USB power adapters arrives in oversize box and easy to use but I want to ask a question that is it create some problem in voltage? I am sure no. Share some more comments but my exams 350-001 CCIE Routing and Switching Written Exam and VCP-310 VMWARE. Then, talk each other about your good posts. Thank You