I've taken my shots at DHL over the past few years, and as you probably noticed, there is a massive comment thread slowly but steadily being built with other complaints about the maladroitness of the corporation, but my most recent DHL experience was positive.
last week, sat down at my MacBookPro in the morning, and noticed the machine was no longer sitting level on my desk. Flipped it over, and realized the battery had expanded severely enough to bend the metal casing.
Luckily the battery was still in warranty (received computer May 2006).
I talked to Apple around 11:01 AM (per my Now Contact record), read off my serial number to the Apple support dude (in Austin), and was told the details of the exchange. I asked if they would use a different carrier other than DHL, but it wasn't an option. However, the next day, DHL delivered the battery without incident, I chatted with the delivery guy about HD-TV while placing my old battery in the package and resealing it. Two days later, Apple sent me a note that the defective battery had been received, and I wouldn't be charged for anything. Coolness.