I had a Savage Worlds Explorer's Edition 1st printing fall apart on me as soon as I used it. Pinnacle replaced it quickly.
There was another book that had problems, and the publisher replaced it promptly, too. I think it was SJGames, but I don't remember what book it was (a GURPS 3e softcover, I think).
Then there's the copy of Atlas Games' Penumbra Fantasy Bestiary -- the first 32 pages (IIRC; it was one printing "signature") were upside down and from later in the book. The rest of the book was fine -- that copy just had an extra copy of one chunk in the front, upside down. I didn't bother returning it.
The first copy of the GURPS Basic (3e) I had fell apart -- the pages all came loose from the cover. However, that was after years of fairly thorough use, including it falling from a moving car (35-45 mph, if I remember where it fell off correctly). I reinforced the spine of the cover with duct tape, and it was (and is) fine -- it was just more of a folder than a book.