Garbz,
I agree with you, and I have exactly the same puzzlement about why the lens should be to 'blame'. When I had the problems with the D40x and the Sigma 30 mm, I did not expect Sigma to offer to fix the lens, I only expected them to offer advice about what to do about an inter-brand problem. I thought that the camera alone was deciding when the lens was in focus, and if the lens misinterpreted the instructions the camera would not report correct focus.
It's easy to see why a lens needs to be collimated/calibrated for a rangefinder or for a reflex camera when accurate scale focusing is required (as it often is in cinematography), but why for autofocus if there are no issues about the exact relative position of internal elements? I'm new to autofocus in still cameras, and I wonder how much of the focus computation is done by the camera and how much by the lens. Does the lens simply respond to the camera's instructions? How, and where, is the acceptable error set in the feedback loop? Is it variable or fixed? Is the final adjustment made by dead reckoning without subsequent feedback confirmation (ie 'if the lens is moved 0.04 mm out it will then be in focus and there will be no need to check')?
Nothing I can find on the web or in optical textbooks gets this deeply, so I would be very grateful for any pointers. The technical guys at Zeiss are always willing to discuss things in great depth and without simplification, but I am reluctant to bother them with a non-Zeiss nitty gritty question. It's easy in motion pictures, because you put all the bits together yourself: the laser rangefinder, the controller, the lens motor...
Best, and thanks for any insight,
Helen