Sounds like exactly what I'm experiencing. As I said, despite the clicking and pausing the replacement drive appears perfectly normal. SMART tests come back clean, no syslog events, and I can stream without a hitch. But in my experience clicking=bad and when I hear from people like betaman who are having no problems at all it makes me want to drop the RMA hammer. I'm quite frustrated.
Last night I hooked up another power supply and moved the drives to different SATA ports with no luck. It is possible that the motherboard is bad (GIGABYTE GA-MA74GM-S2) but I doubt it. I have 2 Western Digital Caviar Green WD20EADS 2TB drives arriving tomorrow. If they both Preclear and function properly I will conclude that the Seagates are defective.
Also, this thread is in no way meant to bash Seagate. I've never been a fanboy of any particular drive manufacurer. I picked the Seagates because from what I've read they are faster, consume less power, and were cheaper than the WD greens. That said, for my purposes (streaming mp3, 1080p) any modern SATA drive is more than fast enough. Regardless of whether my recent experiences with Seagate are the exception or the norm I cannot help but have my confidence shaken if 2/3 drives I've received are indeed bad. We'll see tomorrow.