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Sorry to hear, Todd. I can say is that I have an Aerotrain from the first production run, 10 years ago, I guess. I run it on 031 tubular & have no troubles. One would think that with 036 curves the chances of such problems would be even lower. Some report unhappiness with the "fixed position" four-wheeled Aerotrain cars, also.
I have the Aerotrain...mine is a recent PS2 issue. My engine has the little wheel set also. I usually run it on O-60 and O-72 FasTrack. I do have an industrial siding with O-36 switches and curves so I just tested it out and it ran through them fine.
I'm wondering if that small wheel set is out of gauge on your locomotive. That could cause the derailing.
From what I understand, this a new design for the back wheel set. On the back truck, there is one set of normal drive wheels and in front of those (still on the back set) is a smaller set of wheels, about 1/2 the size. And those are the ones that are derailing. Those smaller ones are not powered.
What was changed? I have an older Locosound version and it has the small wheels. It has never derailed and I have even ran it on 027 curves.
It's possible your issue is something else, but you can check the gauge and at least rule it out. It does sound like your loco is doing what my Williams did.