While I don't know what happens at boot time and thus can't help with your issues, I want to confirm how my CF card is setup to handle a complete reformat (back to Firmware 2.10) or just a reflash.
To
reformat my iLiad, I copy the contents of config-reformat.txt onto config.txt,
otherwise for a
reflash, I copy the contents of config-reflash.txt onto config.txt.
Then insert the CF card and reboot as specified.
See the directory listing of my CF card (and contents of the .txt files) below :
Code:
Microsoft Windows XP [Version 5.1.2600]
(C) Copyright 1985-2001 Microsoft Corp.
J:\>dir
Volume in drive J is ILIADOS_212
Volume Serial Number is B4AF-0502
Directory of J:\
09/19/2009 01:05 AM <DIR> images
08/29/2010 04:53 PM 289 logfile.txt
09/19/2009 12:16 AM 6 config-reformat.txt
07/12/2007 02:56 PM 27 config-reflash.txt
09/22/2009 11:49 AM <DIR> newspapers
09/22/2009 11:49 AM <DIR> books
09/19/2009 05:46 AM 559 logfile-reformat.txt
09/22/2009 11:49 AM <DIR> documents
09/22/2009 11:49 AM <DIR> notes
09/19/2009 05:55 AM 289 logfile-reflash.txt
07/12/2007 02:56 PM 27 config.txt
6 File(s) 1,197 bytes
5 Dir(s) 3,890,176 bytes free
J:\>type config-reflash.txt
kernel
initrd
applications
J:\>dir
Volume in drive J is ILIADOS_212
Volume Serial Number is B4AF-0502
Directory of J:\
09/19/2009 01:05 AM <DIR> images
08/29/2010 04:53 PM 289 logfile.txt
09/19/2009 12:16 AM 6 config-reformat.txt
07/12/2007 02:56 PM 27 config-reflash.txt
09/22/2009 11:49 AM <DIR> newspapers
09/22/2009 11:49 AM <DIR> books
09/19/2009 05:46 AM 559 logfile-reformat.txt
09/22/2009 11:49 AM <DIR> documents
09/22/2009 11:49 AM <DIR> notes
09/19/2009 05:55 AM 289 logfile-reflash.txt
07/12/2007 02:56 PM 27 config.txt
6 File(s) 1,197 bytes
5 Dir(s) 3,890,176 bytes free
J:\>dir images
Volume in drive J is ILIADOS_212
Volume Serial Number is B4AF-0502
Directory of J:\images
09/19/2009 01:05 AM <DIR> .
09/19/2009 01:05 AM <DIR> ..
10/16/2007 09:23 AM 25,930,132 app.image.gz
10/16/2007 09:25 AM 47 app.image.gz.md5
01/03/2008 04:37 PM 1,316,172 initrd.gz
01/03/2008 04:37 PM 44 initrd.gz.md5
07/06/2007 01:13 PM 619,540 zImage.gz
07/06/2007 01:35 PM 44 zImage.gz.md5
6 File(s) 27,865,979 bytes
2 Dir(s) 3,890,176 bytes free
J:\>type config-reformat.txt
format
J:\>type config-reflash.txt
kernel
initrd
applications
J:\>
The only thing I can think of is that when the iLiad boots up, try to reset it before it locks up and perhaps reformat it again afterward. Worth a try...