Ugh. Does anyone remember the 'measurbation' that occured back when the 10d came out? Same exact problems; people shooting rulers and printing out grids that they taped to boxes that got tilted at a 45 degree angle.. sigh.
Serious deja vu. I loved my 10D until I started reading posts about how it apparently backfocused. I didn't know mine did until I tested it. Then I spent a week fighting with myself and wondering whether I should send it to Canon or not, finally did, and it came back front focusing slightly. Then I figured it was my lens, and thought about sending that in. Then I shut up and decided to just shoot.
You know what? I still have that 10D, I still love that 10D, and I still take shots with that 10D. When I got my 20D and my backup XTI, I didn't go around shooting rulers and inspecting shots for a centimeter of backfocus at 10 yards.
I suggest that anyone who feels the urge to "test" their 40d, don't. (I don't have one yet, but I'm sure as heck not worried about this 'problem'; as I will buy one soon and won't think about this one bit)
Unless all your photos are coming out looking like they're shot through vaseline, first try working on your technique, eliminating camera shake, shooting at the right shutter speed, focusing on the right points.. Then, if you still can't get a single sharp shot out of the camera, consider service. But for godsakes, don't sit around here spreading more rumors that there's some "endemic" problem with the 40d.
There were whole websites dedicated to the AF "problem" of the 10D. Now you don't hear a word about it; my guess is that most of the people with the "problem" either learned how to shoot better, or got tired of shooting rulers and moved on to more interesting subject matter.