What FW version is loaded. Have you done any FW updates and used the same configuration file? What browser do you use when saving the config file?
I have always used FireFox. I switched to 2.06NA about three weeks ago. I just manually reconfigured it and saved a new file. No idea how one could work around the pwd. I'm pretty certain that when I updated to 2.06NA that I reconfigured at that point. It's possible that I did not but I was using the same pwd at the time as well and was using 2.05NA previous.
Hey...I'm looking at the WiFi signal connection to the Boxee Box while logged into the DIR-825. It says signal strength is 100% but the "rate" bounces between 58M and 65M. Does say 802.11n for mode. So..in regards to the rate. This is probably just fine as it's showing the "the actual transmission rate of the client in megabits per second" (per the router help file). So this should be actual throughput. I've found that the actual throughput is about 50% of the connection rate. So I'm thinking the connection rate is 130Mpbs and throughput is ~65Mbps.
I did follow up by testing all my equipment on Speakeasy.net and testing dl/ul speeds. All but the Boxee were at 22.xMb down and 4.xMb up. The Boxee Box achieved 22.xMb down on first test and 20.8Mb on the second and both tests 3.83Mb up.