thanks for responding! I'm afraid it's not that easy, though. I'm an IT professional and the support guys from the router's vendor are very capable too (and I don't say that very often about tech support... ;).
The firmware update did not change any settings (at least none that are visible in the router's config UI), but it was a major release, so I'm suspecting it contained updated wifi drivers.
I had set the router to 802.11b+g, WPA2/CCMP and a fixed channel. This worked like a charm with the old firmware version. With the most recent (beta) FW, the TSU also supports WPA2 (and I think it's 802.11g, not b). Immediately after the update, with no settings changed, it stops working. Going back to the old FW release -> works again.
Ultimately, I want to be able to use the updated firmware, so downgrading is not really what I would prefer. Also the router's vendor would like to see the issue fixed, I imagine.
Theres no connection attempts in the router's log even with maximum logging enabled. I suspect something on layer 1, so the issue doesn't even make it to the logs.
The settings in PEP3 don't help either - I've set WPA/WPA2 authentication, the correct fixed channel (which improves connection times a lot, compared to "auto") and of course the correct network key.
I'll let them know that it's probably a Marvell chipset, maybe it helps, maybe it doesn't. Thanks!