3gs replacement stuck in restore mode - error code 6

I had updated my previous 3GS to OS4.0 which crashed it entirely as it rebooted continually thro the process. Good applecare service which have just sent me a new 3GS with 4.0 preinstalled.
Now setting up new phone - asked me if I wanted to upgrade to OS4.0.1 - now only detects an iphone in recovery mode. I try and restore/update but it comes up with error code 6.
I have zone alarm extreme security and have tried turning it all off and restoring as it seems to be interfering with it but with no luck. Didn't seem to have a problem with OS4.
Any suggestions?

That error indicates a hardware failure. If you've already tried restoring multiple times on multiple computers and continue to get the same error, there is nothing more you can do. The phone will need to be replaced.

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