This is a follow up to two threads I posted on this subject over the weekend. I submitted a ticket, got a case number, and spoke to an Apple rep on Sunday morning. She first asked if I tried the reset (which I did - to no avail), and then instructed me to do a restore as a new device. I did, and it seemed to work. As an experiment, I also did another restore (from backup) - my original configuration - and to my surprise ... it still seems to work.
I have been making a conscious effort to firmly place the sensor against my ear (initially) and make sure that my face doesn't touch the display for at least a second, and so far, not a single face dial.
I've given up using my 3gs leather case though ... due to the repositioning of the proximity sensor, it still gives me a lot of trouble. I wrote the case manufacturer alerting them to the potential problem when they come out with their iPhone 4 version.