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Sounds a bit of a headache that one! If you have a chance to I could recommend booking in to your local Tech Bar (www.booktechbar.com) for one of the guys there to have a look at it. At the very least we should be able to acertain whether the device is just faulty and in need of replacement.
If its still within the first 30 days of purchase we may need to send it off through store under the Early Life Failure (ELF) policy for a final assessment to get authorisation for full replacement (just make sure you have the box and all that with you) or if its outside the first 30 days, Sierra Wireless manage all their own warranty claims and can be contacted on 1800 172 244 to organise the warranty replacement.