I wrote up a reply earlier, but internet is cutting out. Verizon been working on it for couple weeks.
First was mentioned the brushes. Some debris could have gotten in there, or the brushes just stuck.
Another possibility is that bugs have gotten in and 1. either built mud nests or cocoons that are causing problems, or 2. bugs, themselves, are causing problems.
Another possibility is a loose connection within the router.
The last possibility was incoming power supply. Your manual states that router will overheat if incoming voltage drops more than 10%. Doesn't sound like what's happening here, especially as you used another router in the same setup.
If you can't find the problem, best to get another router. One with soft start would be nice.
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