Looks like Softbank received a faulty batch of phones because I am having the same issues. Tried every rom/radio combo, but everything fails. ~150ma battery drain. The battery drain issue is getting rather annoying and I think I am going to do what you did and return the pos to softbank to get it fixed.
Did you root your old unit before returning it? If you did, did you unroot it before you went to the softbank shop?
It was rooted, Radio S-off, ENG S-off, Recovery Flashed, running one of the LeeDroid versons (even with -150ma drain with the screen off this rom gave me 6-7 hours vs. 3-4 CM7 was giving me), and I don't remeber what radio but it wasn't stock.
I was drunk at a bar when I knocked it in to the sink behind the bar and by the time I noticed, it was dead. I dried it with a hair dryer when I got home but it would not turn on so after I turned it in to SoftBank I dont think they could tell it was hacked or even cared since it was covered by the insurance.
I think hacking only voids the warrenty not damage protection insurance. Technicly if you brick your phone hacking it you damaged the phone and I assume the insurance would cover that. I only had to pay something like Y8500 and wait 2 weeks for them to "repair" it. They didn't repair anything, just gave me a new phone with a new serial number without the sim/sd cover and gave me my old cover back.
When I got my new phone the 1st thing I did was test it with current widget with the stock rom but the value was 0ma all the time. I went ahead and flashed it because 6-7 hours with LeeDroid was better then the stock rom and to my suprise i was getting the -3ma drain everyone was talking about so I flashed CM7 and still had -3ma standby drain. I thought it was SoftBanks network causing the problem at 1st, not the phone.
I don't think softbank users should assume that its a bad batch of DesireHD's just yet and try to get new phones. It could be other reasons and they should try the troubleshooting steps in the 2nd post 1st and try different rom and radio combinations and if they have tried EVERYTHING, then talk to softbank. I will post part of my 1st and 2nd serial numbers up when i get home and maybe they can be compaired or something then mabe we can confirm a bad batch.