I've been working my way through these DVDs over the last few weeks. At times, the show can be a little... well, "craptastic," as Al himself has said; but there are some really great bits (many of which are the educational films and the fake commercials). But the commentaries... holy crap! These alone are worth the price of the set. Absolutely hilarious!
And let me say that Shout! was really great about sending out those replacement discs. I got mine about as fast as humanly possible after I emailed them!
I'm glad I found this thread as I returned this set twice to Best Buy but now I'm trying to go through Shout for the replacement dvd. EDIT - the e-mail went through. Hopefully, I'll have as much success as you guys.