It seems that a lot of these problems people are having seem to have something to do with current production. Have the specifications changed? Have the components changed?
I do remember Lou Kovach, one of the original designers, once told me that some producers were notorious for changing components or using less expense ones rather then those that were specified. That's why some of the early Lionel/IC controls components seem to perform better with fewer problems then the later production when it was moved offshore.
The system I have is from very early production and supplied after the free ones given with the Legacy Big Boys or Challengers, can't remember which, and after dealer per-orders. It was registered and upgraded and there has never been an operational issue with it. I know the rest of the former TMCC demo group have the same production ones that I have and they don't have any issues either.
So, is it related to recent production?
The original designer is no longer part of Lionel so could the original specifications or components been changed. Could that be the reason that so many people seem to have problems with not just one but multiple units?
Just a suggestion; when you post a problem state when you bought your system or engine and maybe by doing that a trend might be detected.