The phone always disconnects during updates. That's normal. I just let it run and it completes. I think once I had to hit retry, but it always seems to find the phone and complete in spite of the disconnect warning.
I've flashed a bunch of times and this is how it goes...
Hit Start and the update begins downloading. Progress bar appears and estimated time to finish is somewhere around 12-15 minutes.
After only a few minutes (far less than the estimated time) the phone's screen turns black and I get a disconnect warning.
Immediately after that the phone screen lights up all white (blank). Time to finish estimate gets erratic.
A few more minutes go by with the blank white screen. I hear multiple connect/disconnect sounds from Windows, like it is trying to reconnect, but get no indication that anything further is happening.
Eventually the phone screen goes dark and then white again, only now it says:
v 40.2.005 (or whatever version you are flashing)
Local mode
NOKIA
Then shortly after that NSU says it's done and the phone reboots.
I think once I got a warning about pulling the battery, but I just hit retry and it completed. Oh, and once I got some kind of Windows driver error, and I hit cancel update and the phone rebooted into the old firmware.
As for your troubles, could it be Win7? I dunno... with Windows anything is possible. Were you running PC Suite or Ovi Suite? How long did you wait before pulling the battery and trying again, and did you try just hitting "retry" in NSU? Could be you were just impatient.
Changing your product code previously should not be an issue. And yes, Nokia can tell if you changed your product code, even if you change it back later. I've heard mixed reports about Nokia Service. Some say sending in a phone with an altered product code doesn't matter, while others have said they had trouble. Probably depends on who happens to look at your phone.
Sorry you had problems.
