Airport Express is shutting off when running newer firmwares including the latest 7.6.1

Hi All,
My Airport Express has started shutting off in the past month or so after upgrading to the newer firmwares 7.6 & 7.6.1
When the Airport Express shuts off, the status light goes dark and the only way to reset it is to unplug it, wait a few seconds and then plug it back in.
After I plug the unit back in, it works for maybe 15 to 20 minutes and shuts off again.
I googled the problem and I have noticed that others are having similar problem. Some people say that the hardware is failing or has failed. Others have mentioned resetting the unit to defaults and or downgrading the firmware.
So I reset my unit to factory, but it didnt seem to help and the unit still kept turning off.
Next I tried downgrading the firmware.
I tried looking for a way to downgrade using the new Airport Utility on my Mac thats running Lion. However i could not find such and option. So i found the older version (AirPort Utility 5.6) on Apples website that would allow me to do the fimware downgrade.
After installing the older version I managed to find the firmware downgrade function in Manual Setup. I downgraded the firmware to Version 7.3 (the oldest one I could choose). Once the unit has flashed itself it rebooted and came up in the Airport Utility. However It wouldnt allow me to configure the airport. The configuration options wouldnt load at all. This was fixed by resetting the unit to default. After it came back up I managed to set it up to how I had it before.
And since then its been running problem free without any hiccups for the past two days!!
My question is, has anyone seen this before? What could this be? Did Apple release the wrong firmware for my Airport Express Hardware? Did my Airport Express Flash the newer firmware imporperly? Were the settings from the old firmware incompatible with the newer firmware? Is the newer firmware causing the Aiport Express to oveheat or run out of spec? Or does Apple simply not put much effort into testing the firmware updates that it releases?
It would be nice if the Airport Express would flash a colored light instead of shutting down completely if something firmware/software related is causing the unit to crash or overheat.
I would like to know if anyone else has dealt with this problem.

Two likely possibilities:
1) An internal electronic component is on the verge of failure. It works until it gets hot, at which point it changes value and causes a shut down of the device.
2) An internal connector is right on the verge of losing contact. When the device heats up, heat expansion causes a loss of physical contact.
I assume that the Express is out of warranty. It is a real longshot, but you might try to carefully saw open the AirPort Express along the center seam to split the case in half to expose the internal electronics. There might be something obvious.....but unfortunately, more likely not.
Chances are, you will need to replace the device.

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