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And that is where the screen hangs on the player "Starting audio..."
Oddly, doing a Ctrl-C then running ./player -i brings her back. Leading me to believe this is a problem somewhere with the Aux In somehow. The only time the problem reappears is if the player is powered down in Aux mode. Selecting aux while the player is running fine causes it to lock. I think this is the first time I have ever used the aux in on the spare, so something could have been out of whack from day one, and I never noticed.

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I would've have thought the HD controller problem was co-incidental. In my experience a dead chip would crash the player app to the point where the only remedy for me was reflashing the player. However starting the player with -i might solve it had I known at the time, assuming the -i makes the player app default to mp3 playback instead of tuner/aux in.

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As I said earlier in the post, everything would be fine until you select the Aux in (I didn't have a tuner at the time but I'd imagine it would do the same) the player would then lock and it couldn't restart. This was nearly 2 years ago, the unit went back for repair and came back with a different serial number.