Don't know why the older module does not have the comm issues. It would take some more specific troubleshooting to figure that out.
As far as saving the older booter & firmware, we have programs that can do what you are saying, but from your point of view it is not necessary to have these programs. I have copies of all the old firmware and booters. Whatever one you want, I can e-mail to you. Just let me know which one(s) you want (
support@hosteng.com).