I Need A New Router

PS> it's important to get the bandwidth numbers correct for the various ports. If those are incorrect in the router, it'll have adverse effects on performance/balancing/failover if not downright failures like you're seeing. If anything, you probably want to set the router port bandwidths a little lower than the (supposed) actual. Keep tweaking.
Good advice on the port bandwidths. Unfortunately I don't remember off the top of my head what they are supposed to be. Standard Roadrunner and DSL from Alltel but I will have to dig up some numbers someplace.