unless there has been a solder blob or something was not fully soldered and over time it just went from marginal to not connected.
my idea is since the issue is the terminal mapping, then set it inside the configuration to automatically switch on power up and maybe bypass a defect.
this is because the altair can be accessed via external terminal allowing access.
if the configuration change allows the vt100 built in terminal to work then it can help trace what is going wrong.
now on my kits i have experienced weirdness with the switches when the machine sits for a long time. i had the switches not read properly because i would guess there is oxidation inside.
so what i do now from time to time is i cycle all the switches up and down a few times, and i use DEOXIT and i drop some inside the switches from the front, it serves 2 purposes
1) lubricate the switches since they can stick a little
2) help any oxidization with a little DEOXIT that gets into the switch
plus i exercise the switches trying to keep the contacts clean.
i treat my machine a little different in that i make all my changes inside the configuration menu and save them to profile 0.
thus i rarely use the front switches, just makes things easier at the cost of a little less originality.
could it still be a bad SD or Due yeah, but if you can work around in the short term why not plus it can help pin point what is defective.
if the issue is SW0 it would also cause issues with selecting a disk to load.
doesn't the new firmware also have a front panel and switch test?
its amazing how non-related things can also cause problems.
i just had a USB 3.5 disk drive cause some kind of noise that interfered with a WIFI card on the same machine.
makes no sense but you just roll with it.