Pioneer/Onkyo needs to stop messing around & replace the board like they did mine.
Yup, that's what is needed, but they just don't want to do it for some reason. Did you get a report on what they found wrong and/or what they did to repair the unit?
I suspect that the problems we are having with Pioneer's customer service is probably due to the takeover of the company by Onkyo. A few years ago, there were at least 3 authorized Pioneer service centers within an hour's drive of my home. I used to be able to drive a unit to one of their facilities, verbally tell the guy what was wrong with the unit, and then pick it up repaired in a few days - all very friendly is easy to do. Now when I wanted to drive my unit to a facility, besides not issuing an RMA, they said that the nearest authorized facility is in Syracuse, 275 miles from my home. I tried calling the old facilities, and sure enough, they said that they no longer do any work for Pioneer. Pioneer has been dropped from the product line here at AVS as well, though I don't know their particular reasons for dropping them.
Are you as impressed with the 5040ub as I am?
Yes, even after all of these years using projectors, I am still very impressed with the 5040. I have owned many projectors, starting with CRTs from Sony and Electrohome back in the "old days", and digital units from quite a few companies ( a couple of JVCs, Sharp, InFocus, Panasonic, Marantz, and Sim2 just to name a few of them) and the units from Epson have been my favorite. I owned the 5020 and now the 5030, but my friend's 5040 is even better - great projector!
All of them work, but I found that the HDMI cable connecting the X800 must not be stressed/pulled in any particular direction.
Yup, same here, especially with the passive cables, which tend to be thicker and have end connectors that don't fit tightly in the SC-95. The SC-95 over here doesn't ever seem to "drop" the connection - it just never gets started. When we can get it to work, it is not because of the connection quality - it is because we are breaking the connection and forcing HDCP to negotiate over and over again until it works. Once working, moving the connector or stress points on the wire has no effect and the signal remains intact. We really went out of our way to try to prove that this was a cable and/or connector issue, but the symptoms say that it is not. The problem is the negotiation of HDCP 2.2 in the output stage of the SC-95.
Edit: Oops, I just noticed that you said that the X800 was finicky. That is not the same as our situation. Over here, the "finicky"(loose) connection is in the SC-95. Two X800s that we tried were solid as a rock when connected to ANY other gear.