Hi wengi,

thanks for the reply.

- copy the files to your pc and extract them loacally
Done. Works great. The files doesn't seem to be the problem.

- e2fsck the data partition of the asus
Done. No data corruption, HDD is clean (e2fsck -p -f and e2fsck -f).

- check the log files
Done. It is hard to find an entry that has a direct relation with the stall. But around the timestamp of the stall i sometimes can see the folowing entry as an example:
Code:
[2009/09/29 21:11:55, 0] source/lib/util_sock.c:read_data(436)
  read_data: read failure for 4. Error = No route to host
and sometimes:
Code:
[2009/09/30 19:06:01, 0] source/lib/util_sock.c:read_data(436)
  read_data: read failure for 4. Error = Connection timed out
In the nmbd log i often can find the folowing entry:
Code:
[2009/09/30 20:55:48, 0] source/nmbd/nmbd_responserecordsdb.c:find_response_record(235)
  find_response_record: response packet id 16212 received with no matching record.
I don't know if this is "normal" or maybe a hint to the problem i have.

- monitor the 'top' of asus during extraction of the files.
Done. Whenever the WL-HDD freezes, the top output freezes too:
Code:
Mem: 29556K used, 616K free, 0K shrd, 1696K buff, 21536K cached
Load average: 1.45, 0.77, 0.31    (State: S=sleeping R=running, W=waiting)

  PID USER     STATUS   RSS  PPID %CPU %MEM COMMAND
  130 admin    R        364   127  1.3  1.2 top
  126 admin    S        392    93  1.1  1.2 dropbear
  131 admin    D       1604   123  0.0  5.3 smbd
  114 admin    S        500     1  0.0  1.6 xinetd
   73 admin    S        476     1  0.0  1.5 statd
  125 admin    S        464     1  0.0  1.5 nmbd
   50 admin    S        356     1  0.0  1.1 httpd
  123 admin    S        356     1  0.0  1.1 smbd
Again and again i forced a check of the HDD with e2fsck. But it says, that all is ok. But i have found the following:

I decompressed the rar. The HDD freezes, i powered off and started the WL-HDD again. Then i renamed the uncompressed fragment and tried to decompress the rar again. And the it works.
For me it seems, that i have something like a bad sector on my HDD and whenever i cross this bad sector, the whole thing freezes. But i don't know how to solve...

Regards, Thorsten