Hi Chris,
Firstly, no offence taken! I appreciate that this whole episode has been very frustrating for a lot of people.
Maybe I should have explained my situation better, but I thought I'd already said enough! I run a commercial studio facility in the UK and as I said, I am lucky enough to have two DAW's, both fitted with PCIx-424 cards. Obviously this made it easier for me to conclude that it was unlikely to be a hardware failure. Also, I've never heard of a PCIx-424 card failing.
Neither of our DAW's have internet access either, but we do have office computers that are online. The point I was trying to make is that google is a lifeline for anyone in pro audio or video in situations like this. If I have a problem in the studio, you can bet that someone has already had the same problem as me. In less than a minute I found this thread and knew that we had a software problem. A quick call to the UK distributors confirmed this. My advice would be that if you run your DAW offline, then it would be prudent to have internet access by other means. How else would you be able to download the new drivers?
The tech note is the usual unhelpful stuff from MOTU, as is the readme file with the drivers which must be 500 years old by now

. I agree with you that it's all a bit weird having to take the card in and out. I usually don't bother and then check the file versions after installation. I think the card in and out routine is a failsafe method for non-technical people which guarantees everything getting installed correctly.
MOTU weekend support.... I don't know about time zone differences etc., but the new drivers were posted on Friday, so luckily it wasn't an issue for us. Also, it wasn't a hardware problem, so there were no logistics involved. However, if this had all happened at the weekend, and the problem was firmware on the card itself, then it would have been a very different story. I'm sure that if MOTU hadn't fixed this so quickly, then a lot of people would have considered legal action. However, I'd put money on it that legally there would be no obligation for them to pay up for consequential loss (cancelled sessions etc.)
On saying that, I'd like to think that anyone who bought a new card would get their money back, no questions asked.
Yes, it's a bit pathetic that they didn't fess up a bit more prominently, preferably on the home page

. When I found the statement buried inside the tech notes I did actually laugh out loud! What I love is they say that people 'may experience an issue'. Has anyone out there NOT had an issue??
In a nutshell - I'm a firm believer in the power of Google and rely on it heavily. I was surprised that so many people seemed to panic without checking the web first. The info was there.....