Ok, this one really boggles my mind. If this were happening the other way around it would make a whole heck of a lot more sense

Course were never that lucky hehe
So I'm gonna think out loud here and see if we can come up with a probable point of failure.
Digital input from Sat to STB
Digital input from STB to DVI
Digital input from DVI to TV
Compared to
Digital imput from Sat to STB
Analog input from STB to Component
Analog input from component to TV
Our failure points as I see them.
1. Decompression of the digital Sat signal in the STB. (Unlikely as it has to do this for analog as well though there may be a difference someplace)
2. Bad or low quality DVI cable/connectors
3. DVI data conversion to picture in the TV software (unlikely but still there)
Not sure how we would go about isolating these possibilities other than for number 2, buying a different cable. Any thoughts, I'd like to hear them.