I've owned at least a dozen Maglites, over the years, and never once had a problem with any of them functioning perfectly, with the exception of a Mini Mag 2AA, which I messed up, out of my own boneheadedness, trying to do a Nite-Ize LED upgrade, and foolishly removing the little plastic piece - the part that clearly says "DO NOT REMOVE"; and Maglite shipped the replacement parts (and the installation tool) to me for free. That was maybe a year or so, ago.
I've gifted most of my Maglites, but kept a handful, and have customized almost all of them, in one way or another, though. I don't think it's unreasonable to expect the customer to pay for the return shipment; and maybe a bit odd to charge for the returned/repaired/replaced item; but if it's clearly stated in their instructions (Well...at least, now, with their newer lights), I don't see the problem. Warranty policies sometimes change, over the years. That's life - cost of doing business.
If you have a cheaper Maglite, and are unwilling to pay the shipping costs, and it simply needs parts, replaced; and if you're willing to do the repair, yourself (replacing a faulty switch, switch cover, spring, etc.), I would imagine they'll still send you the parts for not a lot of money. I was kind of surprised when I wrote about obtaining a replacement rubber switch cover and they wanted to charge me for it, but considering how many other Maglites I had owned, and that the cost was very small, it didn't bother me that much. I've had that light ten years, so I got much more than my money's worth; but decided to buy and install a Malkoff 2D 270 lumen XP-G Drop-In, which works beautifully, and has transformed the light from an ordinary 2D light to a real thrower, with a beautiful, defined spot and decent spill beam.
The way some of these lights get abused, I'm, frankly, not terribly surprised that they are finally charging a small fee for the replacement/repair of those items, and some of their parts. They still make a pretty solid product, although they are no longer my first choice, in flashlights, since there are so many other makers that offer equally (or more) reliable products, with many more options (modes, tints, etc.), and offering excellent customer service.
On the flip-side, they (The "D" lights) do make great hosts, for customizing, and a lot of users use them, as such - which I'm sure voids the warranty; but still...
Anyway, to the person who mentioned that it wasn't cost-effective to make a return on a cheaper light - which light did you have (Was it a Mini Mag AA?), and what was the problem with it? You may be able to get parts from them for free, or very cheap, and do the work, yourself. Just email them, describing the problem, and they WILL help you out.
Just a suggestion...
http://i1268.photobucket.com/albums/jj571/david57strat/119_1928800x600.jpg
Back when I was in my Maglite phase - long before I discovered the many other lights that are now available (My pre-true-flashaholic days)
Your images are oversize, when you post an image please remember Rule #3
Rule #3 If you post an image in your post, please downsize the image to no larger than 800 x 800 pixels.
Please resize and repost. - Thanks Norm