Can you test with a 3 numerical combination then test with a 10 character number combination to see if this sticks...
Well, I tried to reproduce the original problem with the **same** password after dinner and so far have been unable to do so.  (My existing password is as complex as I could make it -- 15 characters mixed upper and lower case letters, numbers, and special characters -- and I have not tried a simpler one since my original experimentation on how much complexity I could get away with, reported elsewhere.)  I went through five separate power cycles, unplugging the "wall wart" twice and shutting down the UPS that powers both the router and the cable modem three times, without a password glitch.  (During the middle of this process I saved another configuration file and studied various pages to see what connections were reported -- more below -- but I have never attempted to restore one of these configs as I don't really need them.)  No idea what was special about the one time that the DIR-645 lost its password, though I haven't controlled for connected devices or very much else...
I **really** appreciate your checking out your own system in parallel with my tests.  I guess we can hope that the original post resulted from loading F/W package that was incompatible with the H/W, as you suggested.  (I certainly hope D-Link issues a European version of F/W 1.03 soon and that aeon07 posts back with results from testing that!)  Anyhow, I'll watch for the problem on my end and post back if it repeats...
I noticed two anomalies during this testing:  1) Sometimes one of my Windows XP computers reported an IP address conflict after the router was powered back up, after which I logged off and on again to make sure it was straightened out.  2) I'm still noticing that the F/W reports flaky lists of connected devices.  There seem to be three places where such lists appear:  Status/Device Info, which appears to report mostly wired connections, Status/Wireless, which reports only wireless connections and Setup/Network Settings, which is very inconsistent about what it reports under "Number of Dynamic DHCP Clients."  Have you observed this?  If so I guess we just have to live with it and/or try some other tool like FING to see what's really on the network...
You continue to provide an invaluable service to the communtity (that one might wish were rivaled by D-Link's own tech support!).  Best Regards. -- jclarkw