jmsala, the GPU most definitely heats up. The CPU testing was pointless. When I ran games on the 9600 - and I'm talking old games like 4x4 Evo 2 that don't even begin to tax a modern graphics card - iStat Pro reported my GPU Diode temp as high as 100°Celsius. There is a definitely a heat a problem. Doing a PRAM reset got the fans to come on properly for exactly one launch of one game, after which any subsequent launch of any game inspired no fan ramp-ups. An SMC reset (powering off, removing battery, holding power button for 15 seconds, re-inserting battery, booting up) had the exact same effect. Fans worked correctly for exactly one program run then never again. Combined hardware/software problem I'm pretty sure. I quit using it altogether because I know that those high temps are destroying the hardware even if it isn't blatantly obvious in the immediate.
I keep seeing people talking about stressing the GPU and such which is why I keep reiterating that I only use OS X, have no Boot Camp/Windows partitions and don't use anything like like Parallels. I only have old games like 4x4 Evo 2, Quake 3, Medal of Honor Allied Assault, and more along this line. Games from 5+ years ago that have 64MB or less VRAM requirements. The 9400 plays them all on max settings with only the rarest occurrence of fan ramp up, and never a failure of any kind. But the 9600 GT can't handle any of them without overheating and taking out my display. I don't have ANY modern games save for Flat Out 2 which of courses locks up just the same.
This is not a particular game issue, and as demonstrated on my system this isn't even an issue of putting a heavy load on the 9600. We have heat issues but little reason for the overheating. If the 9400 doesn't get hot (it doesn't) nor fail (it doesn't) when playing these games, and the 9600 overheats and fails on the same game within minutes or seconds, I think we have all the evidence we need of faulty hardware. I think the question now is whether or not it is a bunch of bad chips or, more seriously, a completely bad design that was rushed to market when it shouldn't have been. I don't think there is going to be an easy solution to this.