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Absolutely NEVER have had that problem before, and we have updated about 65 of the iLive-Ts and iLives to V1.51

Sounds to me like your upload got corrupted, or there was an issue with your USB Key and it didnt write the code properly. some type of gap maybe.

I would reset your system back to 1.43, the use a different USB key and re-download the firmware, the do the update.