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I've had the same problem with my Dell TM 1150. I think the solution will be to find a third party raw writer/reader that will program the flash in the card, then find a binary image of the firmware you want to use.
(Alchemy comes to mind..)
I have tried the "hacking the old update code" with a hex editor, but I must have missed a step somewhere.
It doesn't seem possible to go back to an earlier flash using the standard Windoz apps due to the driver issues you've mentioned.
I just kind of gave up on it due to time constraints. I might take another swipe at it down the road sometime.
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Try a tube of the new lube,
Obamacaine!
They won't feel the shaft until it's too late!
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