I'm taking a stab at this, because I have a Samsung HLN5065W DLP TV. On my TV, only Component Inputs 2 and 3 handle 480i, 480p, 720p, and 1080i.
Did you get the new HD-UI firmware update prior to your return? Possibly your Display format settings got reset to SD, 480p, after the D* update. This happened to me on the last two firmware updates. I had to go into the DVR Setup and select all but 1080p which my TV will not handle. The strange thing is my Sony LCD and HR24 never resets. Best wishes!
Did you get the new HD-UI firmware update prior to your return? Possibly your Display format settings got reset to SD, 480p, after the D* update. This happened to me on the last two firmware updates. I had to go into the DVR Setup and select all but 1080p which my TV will not handle. The strange thing is my Sony LCD and HR24 never resets. Best wishes!