The method I used to successfully request a replacement card:
Log into Paypal. You'll be presented with the 'Accounts' screen. On the right hand side, you'll see "Questions? We're here to help." with a light blue question mark (?) to the left. Underneath that is a link labeled "Contact Us". Click that and you'll be taken to the contact screen.
Under option 2, click 'E-mail Us". In the frame to the right, you'll see another "E-mail Us" link. On the next screen, under "Ask Your Question", select the radio button next to "Paypal Debit Card" and then the radio button to the left of "Card Stolen/Lost/Replace". You'll need to enter some text in the text box at the bottom of the screen, such as "My Paypal debit card is cracked in half and I need a replacement". You must enter something, but don't bother making it too fancy. It's another way to herd you into another ineffective self-help/knowledgebase option.
On the last screen titled "Contact Us", you'll be able to send a message through their web form. You'll receive an auto-reply from the Paypal system, and then about 24 hours later you should receive confimation from the Paypal Debit Card Team letting you know that a new card will be sent.
