Same Issue
Lost my Droid 2 on St. Patrick's day, called Asurion.
Got a D2 replacement that was broken (refurbished junk). Called again, got a phone that was half R2-D2 version half Droid-2 (refurbished junk).
Called yet again, said I wanted a new phone, was offered a Droid 2 Global, got it today.
Ran one battery down, put in a second. Someone called me and I could BARELY hear them, like 1% of normal volume, clearly a bug. (Angry).
Called my voicemail to test, same hearing issue, sounded like the speaker was damaged.
Searched the web, saw that you can pull the battery to "reset" it, this seemed to fix the issue. However, since I use multiple batteries....this problem will RE-OCCUR every so-often on a battery pull.
Unacceptable. I use this phone for business and I'd rather have a broken beat up Droid 2 (refurbished) that has 100% reliable volume/sound in a call that a shiny new Droid 2 Global that might or might not work when an important business call or client comes in.
This issue seems to be widespread, and it is absolutely unacceptable. I am so sick of this run around with the insurance company I don't know what to do. Buy a blackberry?
(Firmware claims to be up-to-date when I try to force an update.)