Thanks again, so it's the DMA parameters. The bad thing is that switching to those old parameters hurts wifi for me, the transfer becomes less stable, I get ~200kB/s fluctuations (to the slow side of course), while with problematic parameters it's much more stable.#1138 also works like #1137. No squashfs errors. PaleMoon recovers every time. Thanks!
The obvious solution is to only set the new params for wifi and revert them for SD cards (they don't help SD card rates anyway), so could you do one more (and hopefully last) test? I'm almost sure it will work, but it would be great to have your confirmation.
The file is the same as always: http://notaz.gp2x.de/tmp/uImage-3