We can't discount less-than-great shipping practices when returning stuff to LIONEL.
I hope you guys aren't just shipping these things back to Lionel in their "shipper" sleeve...that's pushing your luck for sure.
Gotta double box - and make sure it's a system they can re-use easily when returning your train.
You'd think they would note apparent shipping damage on inspection - like "hatch appears to have popped off in shipping with possible paint damage." - just to CYA.