I had the same problem. I went through two replacement phones until they sent me one that didn't click or creak. It is a quality control issue if you ask me. I believe it is how the plastic housing rubs against the internal stuff when you press hard enough on the screen. If you look carefully you will see that the screen will also push in slightly when you put enough pressure on it. I wouldn't settle for it. Refurbished phones certified like new often are better. They usually are totally rebuilt and go through a 100 point inspection. I would do it and get one. You wont be disappointed. I really think HTC dropped the ball with the thunderbolt when it comes to build quality. The build quality of my last HTC phone, which was the Incredible, was great. There is a big difference. Its easy to tell. If you get a refurbished phone it should be fine and better. You spent a lot for this phone. Don't settle on something that bothers you. If the refurb doesn't meet your expectations send it back and demand another. They will send you another. Keep doing it until they get it right. This is a great phone when all your expectations quality wise are met.