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Probably not helpful to you now, but a few things you can try if the problem continues when you get it back. This is based mostly on my 27" 2010 iMac. The computer was working good when I bought it, but if came with a free upgrade to Lion so I installed Lion about a week after getting the machine. I immediately started having issues with keys sticking on my wireless keyboard. I though since it was new I just had a bad keyboard. If a key stuck during boot it would not boot correctly. I called Apple and they recommended taking the keyboard in to be fixed or replaced. Since I was using a USB replacement I had on hand I decided to wait until it was convenient to get to the store for me. As I started using my old software I had issues with Lion incompatibility so I downgraded back to Snow Leopard. On a whim I turned on the wireless keyboard and I have not had another issue with stuck keys (It was not a mechanical problem, but a software issue). So if you have a wireless keyboard consider that.

Another thing you could do, though time-consuming is to pull out all your hard drives (unplug all USB devises) and replace with a single hard drive. Do a new install of your OS and try booting and see if the problem occurs. If it does you most likely have a hardware issue. If no problems add one by one your programs and their updates and boot several times as each one is added until you find the conflict. I had to do this on a PC years ago and as I recall it was a video driver that was causing the issue.

Hope you get it going soon. Sounds like a frustrating issue that has been going on way to long. Apple should have been able to resolve this in a more timely manner.
 
A good update. Finally got a call last night that I could pick up my Mac pro but not the 30in Cinama display. They had finally replicated random the problems I had described but it was not the Pro or its graphics card but the issues with the ACD which they are sending out under warranty for repair. I'm going to get a 23" non Thunderbolt ACD to use until the 30" comes back. I'm happy they found the problem after all this time.

Anyone have pros or cons with the 23in ACD?
 
A good update. Finally got a call last night that I could pick up my Mac pro but not the 30in Cinama display. They had finally replicated random the problems I had described but it was not the Pro or its graphics card but the issues with the ACD which they are sending out under warranty for repair. I'm going to get a 23" non Thunderbolt ACD to use until the 30" comes back. I'm happy they found the problem after all this time.

Anyone have pros or cons with the 23in ACD?

Hi Check 6, Good to know your Mac Pro's fine. I am using a 23" ACD and it's doing fine. No problems. But this it the older model , the one with the acrylic case and 3 legs. It's more than 7 years old and the image is still sharp, bright and the whiteness is still white. I am assuming you are referring to the 23" Aluminum model? I don't know of any disadvantages or cons with that model.
 
Have the MacPro at home and instead of the older 23 in LCD I bought the current 27" LED cinema display to serve me while the 30" ACD is in for refurbishing and repair under warranty as it was the core of the problems.

May even sell it when it comes back as initially I am very happy with the 27" and even though it is not a matte screen the resolution is fantastic and the glare is very minimal, plus it fits better on my small desk.

A very happy camper and well pleased with the service I got from the La Cantera San antonio Apple Store. Sorry for the plug but they deserve it for all they went through to find these random but irritating problems
 
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