If the card has been lost or stolen, they will make you pay for a new one (we lucked out the one time because we were getting "new" passes and pointed that out to them). The only way to get a free replacement aside from getting pixie dust is if your card has been damaged through no fault of your own (i.e. through normal wear and tear) and you have the card with you and can prove it is not working properly in the parks. Once I had a barcode that was rubbing off (due to a batch of bad cards they got) and would no longer scan at the registers for discounts, who told me to go to the ticket booth to get it replaced. Well, it scanned just fine at the ticket booth, so they wanted to charge me for the replacement, I pushed back, but really they want to charge you for a replacement no matter what.