When you are able to get into privileged mode, copy the config to a file to save it. Then do a "write erase" on the console. This erases the NVRAM. I would then reboot the router and copy the config file back into it. Make sure to end with a "write mem". This might be a solution for your problem; I do believe that your NVRAM will eventually die. Sometimes clearing and rewriting NVRAM solves these kinds of problems. If not, then I think you might want the swap the router.
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