Loosing Airport Connections - Core Duo

My AirPort connection doesn't work on MacBook Pro handed to me. No bars in the AirPort menu, no network shows.
MacBook Pro 15", Intel Core Duo, 2.16 GHz, 2GB RAM
Running Leopard 10.5.4 with all other Apple updates
AirPort Extreme (0x168C, 0x86 - Atheros Card), Firmware: 1.4.3.1
Every once in a blue moon, when the Mac was off for a while, it asks to connect to any wifi network around. It rarely connects to the selected wifi network and then only for about 5 minutes before it degrades constantly (watching it with iStumbler) and in about 5 minutes it's dead. When it connects iStumbler never shows more than about 50% signal strength.
In order to get a signal at all I must be right next to the router, only to die after 5-10 minutes. If I try to join the network, it throws a "connection timeout" error.
System.log reports:
Jul 5 15:27:16 localhost kernel[0]: AirPort_Athr5424ab: Ethernet address 00:17:f2:4b:c1:c0
Jul 5 15:27:39 klunker airportd[57]: Could not find any preferred networks; trying broadcast requests..
Jul 5 15:27:42 klunker airportd[57]: Broadcast requests also failed..
Jul 5 15:27:43 klunker airportd[57]: Probing highest ranked networks via directed scan..
Jul 5 15:28:44 klunker SystemUIServer[90]: Error: airportd MIG failed = 1 ((os/kern) invalid address) (port = 25967)
Jul 5 15:29:35 klunker airportd[169]: Error: __ACNetworkAssociate() failed to find Hoefts
Jul 5 15:29:35 klunker SystemUIServer[90]: Error: airportd MIG failed = -6 ((null)) (port = 25967)
Jul 5 15:29:35 klunker airportd[169]: Error: processcommanddict() failed
Jul 5 16:00:37 klunker iStumbler[172]: Exception raised during posting of notification. Ignored. exception: '* -[NSCFArray objectAtIndex:]: index (-1( or possibly larger)) beyond bounds (0)' invoked observer method: '* -[AirPortPlugin tableViewSelectionDidChange:]' observer: 0x191750 notification name: 'NSTableViewSelectionDidChangeNotification'
This happens on various networks (not just my home network with a Netgear router - mixed b/g, channel 6, WPA)
I first checked on my router (switched channels, removed encryption, updated firmware, reset everything). Tried different wifi networks. Nothing would improve it.
I've tried all of the Mac solutions I could find online:
Removing the airport prefs, booting into safe mode, turning IPv6 off, DNS entries, removing and adding the Airport setup, turned the airport utility process off (I use a Netgear router), reset PRAM, Repair Permissions...
I even reseated the card and the antennae (2) in case it was a bad connection.
I finally erased everything and installed from the original disks 10.4.6 and tried upgrading slowly (tried 10.4.6, 10.4.11, 10.5.0, 10.5.1, 10.5.3, 10.5.4), all the way up to 10.5.4.
iStumbler or AP Grapher find the network at the signal strength of about 20% while the Airport menu indicator can't see or connect at all.
Any help would be greatly appreciated.

Have you connected to the router using an ethernet cable? Try this to check that the signals are getting to & through the router. From my own experience it is most likely the wifi connection that is not working as it should.
Make sure that you also do the routine maintenance things such as using Disk Utility to repair permissions. Errors here can affect some processes.
I suggest that you also report the problem to Apple by clicking on the Contact Us link at the bottom of this page. On the screen that comes up choose the most appropriate link at the lower end of the RH column. I would include this copy of the System log. This is the main way we users have of getting Apple's attention. They don't promise any direct response but they will check the issue. You should also give them info about the router(s) you have had this problem with & any other info that might help them sort it out.
Neville

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