wow...i think before you send it in, you might try to bench run it, and put it in a completely different environment than on the airplane. that way, and hopefully you can replicate the problem, it will reduce the possibility that send it in and get a call back that they couldn't find anything wrong. regardless, good luck, this sounds like it is unbelievably frustrating. re: the battery thing, i don't think we talked too much about that, but if you are using a pack that shows good voltage after the deadstick, that would pretty much rule that out as a cause.

P