I am currently trying to decide between the Leveno t400 and the
e6400 from dell, but this overheating issue is a pretty big deal. So big, in fact, that it might be a showstopper. I am a software developer, so I am frequently pushing my machine pretty hard, with running database software such as Oracle and Microsoft SQL Server, and I also run stress tests for the software I write. So suffice it to say that this machine is going to get some pretty hard-core CPU work. Of course, maybe these overheating problems are more related to the graphics activity instead of the CPU? It's hard to tell from this thread.
I currently have an Inspiron e1520 for my home machine, which has been a disappointment. I do a lot of contract software development work on it. The backlight just went out on it and I am having to get it fixed which is going to be about $245. Once I get it back, I immediately plan to send it to eztradein.com and get a few hundred out of it, which I plan to put towards a new laptop, this time, a business class one instead of consumer grade laptop. The inspirons really don't seem to be able to hold up for what I use it for (powered on 24x7, heavy stress testing, etc). And this time, I plan to get a full 4-year on site warranty (I rolled the dice on my Inspiron and just got the 1 year warranty that came with it, but now I'm paying the price, literally

).
I have done some research on this overheating issue, and this isn't the only place it's been discussed:
For example, read fantomex's review here:
http://reviews.dell.com/2341/1542/reviews.htm
Also, here's another good link that shows how dust accumulates in the fan:
http://en.community.dell.com/forums/...px?PageIndex=5
I have a dell d630 for my work laptop, and it's a pretty good machine although the 5400 RPM drive is much too slow (it gets bogged down with all the company software we have running such as Norton, our phone software, and other stuff).
So my post boils down to these questions:
1) For those of you having the overheating problems, do you think this is a design flaw with the e6400 itself? Is a BIOS fix going to be enough to fix the problem?
2) It seems to me that the dust in the fan issue isn't going to be solvable by just a BIOS update. Is that going to be an ongoing maintenance issue with this model?
3) If you had known about the overheating issue before you bought the e6400, would you have gone with the Leveno T400 instead?
4) What made you pick the E6400 over the T400 (as best I can tell, most folks get it narrowed down to those 2 models, and then it's gut wrenching to decide on which to buy, which is exactly the point I'm at now

)
5) For me, the main thing I don't like about the T400 is the fact that CTRL/FN are switched on the keyboard (i.e. the FN key is at bottom left instead of CTRL). Different people have said this is a showstopper, while others have said, "you get used to it". I like the Dell keyboard because it's what I'm used to, but honestly I'll be using an external keyboard mostly, so I guess it's something that I wouldn't necessarily call a showstopper. Just wondered how the keyboard was on the e6400, and if it's as good as the D630. Also, does the track pad or pointer cause any problems (I've heard that it's easy to accidentally hit).
I'd appreciate any feedback you folks might have, I really value your opinion. This overheating thing is pretty worrisome though, because I'm certainly not going to be using this machine to just do casual email / surfing, I need a hardcore machine that can handle a heavy load.