Mike,
Not sure what the story is there. Often times we'll see erratic behavior from the device when battery voltage is dropping below the brown-out points of the processor and voltage regulator circuits. This is usually caused by a battery concern. I had similar issues with my Expedition and shortly after the programmer issues arose (a few weeks I think) I ended up with a dead battery. This has happened twice since we owned the Expedition and both times it was a precursor to a battery concern.
Now I am not saying that you definitely have a bad battery, but historically it's shown that it may be something you want to investigate. If all that checks out, we can RMA the device and see about getting it repaired. I know our Gryphon still works like a champ and it's almost 5 years old, but we don't have the heat that you do either.
Please be aware that it's long since out of warranty, but if there is a problem with the circuit board, it can be replaced for about $200, which is still far less than purchasing a new programmer.
Anyway, let me know what you find and we'll help however we can.
Take care.
__________________
Bill Cohron - The Mad Doctor  
Power Hungry Performance - The ORIGINAL in Ford performance tuning... Since 1996!
(678) 890-1110
www.gopowerhungry.com - Home of the Hydra Chip, Minotaur Tuning Software, and the new Orion Reflash System for Navistar!
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