Have a DIR-835, on the second one and it is on its way out like the first which has its wired ports died. The first router ran stock firmware v1.02 and v1.04, lasted 11 months, the current one is running DD-WRT and so far lasted 15 months. Got a TP-link AP on order to replace this one so now its time to experiment with it in its dying days to see if I can make it last a little longer until its replacement arrives. Router is used only as an AP and all unneeded features except for WMM are turned off.
I took it apart, and noticed the LAN and WAN ports are wired right into the main CPU on the board after the chokes. This happened to be the hottest chip by touch on the board and all it had for a heat sink was a 0.5 sq in thin ceramic plate (this is absolute junk for heat transfer).
Mode of operation: Access Point (routing disabled), WPA2/PSK personal, WAN disabled, 5Ghz channel 137 - 802.11n HT40 300Mbps, 2.4Ghz disabled, gigabit Cat5e on port 1. Internet connection is very healthy 200/10 nat'd through a 3.2Ghz Core2 Duo PfSense box and my tests max the connection over the wifi.
The Experiment:
Steps taken:
1. I re-flowed the board with a heatgun, focusing on the main CPU, suspecting that thermal stresses probably cracked the SMD mounted CPU's mini solder-ball joints.
2. Added a modified copper heat sink + TIM stolen from a piece of **** 100W Mastercraft car inverter, all held down by tape+elastic band over the main PCB
3. Router relocated to open space (it used to be in a cabinet with the doors wide open).
Currently the router doesn't make it past 24 hours without a lockup of the CPU and the connection dropping.
Validation: Lets see how long it goes till the next crash. Next time it crashes or in a week I'll update the thread.
Cheers,
Donald