After having "real life" get in the way for the past day or so and also deciding I'd back away from this problem before I took a hammer to that box, I got back on it last night and found out what the problem is/was!
Post #16 and 18 and a couple of others have the source of this problem listed but no one picked it up and pwrsurge, if you did indeed try to duplicate my problem then you didn't do exactly as I did when doing those scans.
But first, let me set the stage for how I got into trouble to begin with. As Stargaze mentioned, he uses a TP frequency of 3600 for his "dummy" TP. Years ago when I first did my channel list I did the same, ie, had 3600 and 11700 for my "dummies" and that has worked well for me over the past few years in both boxes. Each time I did a rescan of a satellite I always delete all but the "dummy" TP and that operation required me to press 3 buttons on the remote to delete each TP, ie, AZBox defaults to lowest TP number (which was also my dummy) so I have to arrow over, then press delete, then press OK. Smart and lazy me, (insert the word dumbass here also) I decided that I'd move my "dummy" TP numbers out to the upper end of the frequency just to do away with ONE arrow button push when deleting TPs and since there are some TPs up near the end of that frequency range I just decided to use 4205 and 12205. WRONG!! I finally figured out that these numbers being outside the normal range of the default scan settings is what the problem was. I went back and changed those "dummy" TP numbers back to 3600 and 11700 and all is well now!
The reason the scans didn't work with fresh firmware installs and default channel list is because each time I created 78w, the one TP number I always put in was 4205 and or 12205! Did the same thing too with other sats that I scanned??
So, I broke one of my own rules I use where my race car is concerned, ie, NEVER CHANGE BUT ONE THING AT A TIME, and it bit me in the ass big time!! In my case I decided to change my dummy TP numbers at the same time I changed firmware! Note, insert dumbass comment from above here again!
Ennywho, thanks to all for trying to help with this and I guess the up side is we all now know about another of the AZBox quirks!