Mine is in the repair shop now for the same reason. According to their tech support it needs a new DMD chip. The DMD chip is the foundation of DLP. It's a chip about the size of a matchbook with thousands of microscopic mirrors on it that are each mounted on devices that swivel - thus projecting the light/dark images on the screen. My HD66 is 11 months old with about 400 hours +/- and the chip went bad. Fortunately it's still under warranty.
From Maryland via UPS it was $101 for overnight, $60 for 2nd day air and $15 for ground freight which takes a week. I spent the $15.
So figure a week to get there, they say they have it 5-7 business days (of course provided the replacement part is in inventory) and no doubt the cheapest return method (I'd guess ground) for another week - or 3-4 weeks for repair and return. I'm still waiting on mine. They got it last week (Tuesday) and a status check reveals no progress
If by chance the chip is on backorder...........I'll likely go buy another projector and use the '66 as a back up.
I purchased mine with my AMEX - doubles the warranty and kicks in when the original warranty expires. If I get a problem during the 2nd year AMEX will refund the purchase price - schweet. I've used their service before and it works.
I'll post an update when I get my projector back.