I discovered a crack in the Retrax cover toward the front along the channel that the lexan is attached to. The crack is about 36" long, and tapers from 3/8" to 0". It runs from the passenger side to the left. It is in the lexan, not the aluminum channel. I called Retrax and spoke to one of the technicians.
He asked me for the serial #, which is on a sticker under the cover next to the lock. He knew right away about the defect, and said that they used a chemical along the channel when they the assembled the cover. The chemical caused a reaction in the lexan, which caused it to crack.
I called them last monday, and they shipped me a new cover that will arrive this Monday 6/26/06. He told me to take the lock off the cover, and slide the cracked cover back and off the tracks. Installation is just the reverse. Seems easy enough, and their customer service couldnt be better...

Vinnie:D