Just got off the phone with Canon, theyre shipping me another one tomorrow. They charged me for another one and will credit back once they receive this one back. Not to happy with the QC and refurb dept right now but Customer Service was excellent!
I think you have to accept there will some variation in quality if you are purchasing a refurbished body and it must be quite hard for Canon to determine what amounts to an acceptable standard, given there are so many different dimensions to that. So, at the margin, some refurbished bodies are not going to satisfy customers.
In this case, the camera was outside your own limits of acceptability (although somebody else might have been content with it ... and might yet be). It seems you are getting good overall treatment from Canon and I wouldn't feel too harshly towards the QC and refurb dept. A few unacceptable copies and some extra hassle for people like yourself who get something that does not meet their expectations is, I think, a price worth paying for having a good supply of refurbished stock available at good prices.
Your inconvenience on this occasion was just part of the price. Hopefully you will have better luck next time.