A year ago, I sent my model 650 back for repair. I got on the Taurus website, filled out a repair form, printed two copies, put one copy in the Taurus box with the pistol and then bubble wrapped it. It went into a standard cardboard shipping box. USPS will NOT ship handguns, unless you have a FFL registered with them. UPS and FEDEX require your to pay 2nd Day Air costs ($50 from Texas to Miami). I chose FEDEX - I insured the package, and told them that I owned the gun and that it was being sent back to the factory for repair. Read the rules on FEDEX website - Taurus will send the gun back the same way it comes to them (FEDEX in my case) to the originating address in a few weeks. They will NOT notify you that they have shipped it. Call the 1-800 service number, and give them the serial number to find out the status of the gun. FEDEX will only deliver if a person over 18 signs for the package. Warning - they will send the gun back to TAURUS if you don't come and get it quickly after they leave a notice at your door. The carriers (UPS and FEDEX) do not like handguns in their facilities and will be quick to get rid of it and potential liability.
Lots of info - PM if you have more questions.