I know what you are talking about now - there is a little hairline crack down by the power plug. And I really baby this unit - I keep it in a padded nylon case that protects all sides of it.
It doesn't affect the operation of the unit, but it bothers me.
I have also. First came between USB -plug and Audio-plug. I think 770 was only 1 week old then. Another came between USB and power few months after that.
Defect in manufacture or faulty design I think.. No one is too rough-handed with this kind of device when they are only 1 week old.
i have the same problem, some little cracks in the surround of bottom connection, i suppose that this is a separate parts that was forced on to keep close the bottom and top side of the main body, so it's a kind of fuse of every tension inside the chassis!
The first one come out after few weeks the last one last week after 8 months!
I bought it the second they came out in the US - November of last year or a little before? Anyway, a friend of mine that works at CompUSA sold me the first one they received.
Just about everyone will get it eventually. There was too much interference between the case and the plug. Hopefully the mold was revised to take that into account...