POSSIBLE FIX:
I've posted this on another thread with a similar topic. I understand that this might not apply to those of you with beand new Lion machines, but I do believe this will fix it for those who upgraded from SL, due to a corruption in the Keychain. So. Here's the letter I've posted elsewhere:
I'm a certified Apple Consultant and this fix worked for me on a client's home network. I present it without any warranty/guarantee/promises, etc. Use at your own risk. Don't try this if you don't know what you're doing. Please infer any of the other usual legal ramblings.
Client had a Linksys E3000 with Cisco software. She had an Apple Store Genius upgrade her MacBook Pro from 10.6.8 to 10.7.3. Upgrade was uneventful.
When the client returned home, she noted that every time she put the computer to sleep, logged out or rebooted, one of two things could happen:
1) Her network could not be found and it did not automatically reconnect. She could only find it through looking for networks manually in the Network Preferences pane.
2) Network scanner located the network, but asked manually to join an already-known home network and requested the password every time.
She did not have the same problem on other networks. Only at home. Consequently the Genius Bar could not recreate the problem to help, and several calls to AppleCare failed to resolve the issue. Then, I got the call.
I imagine if you're reading this, you've also frustrated yourself with all the usual potential fixes: deleting System Confguration files, rebuilding the WiFi config, clearing PRAM, reparing permissions, changing the WiFi channel, etc.
I'm here to suggest the problem can only be addressed on the router side. Yes, I firmly believe this is a Lion issue, but nothing you do in Lion -- including reinstalling the OS -- will fix this problem if it happens to you. So here's what I finally did:
1) Upgraded the router's firmware to the latest version.
This did NOT solve the problem.
2) Completely reset the modem to factory settings and reconfigured it.
This still did NOT solve the problem.
3) Completely reset the modem to factory settings, reconfigured it AND changed the WPA2 password.
THIS FIXED THE PROBLEM. I waited 5 days to post this to ensure that it was still functioning properly for the client. It is.
Here's the vague theory behind it: Something about the upgrade to Lion also corrupted her Keychain. I can't go into details, because it would take forever and I'm only partially sure I understand it myself, but suffice it to say that there were other Keychain-related issues. No matter how many times I rebuilt that WiFi configuration or messed with system files, it came back. Even deleting the Keychain items related to this network didn't take care of it (and honestly, one of the items reappeared immediately after quitting and relaunching Keychain Access. I saw it with my own weary eyes.)
Once the WPA2 password was changed on the router, it forced that router's profile to be re-saved to Keychain, and I think that made the difference.
I'd like to add that I feel strongly that it was a combination of things that finally fixed it. So I believe following the instructions below will solve the problem for many of you. Please report back here if it does work! As you can see, many people are having this problem.
1) Delete the WiFi profile in Network Preferences.
2) For good measure, you may also want to delete the file /Library/Preferences/SystemConfiguration/com.apple.airport.preferences but I don't know if this going to be necessary.
3) Update the router's firmware to the latest version.
4) After it has been updated and restarted, Completely reset the router to factory settings and start the setup from scratch. DO NOT USE THE SAME WIRELESS PASSWORD AS BEFORE. This is the crucial part, I believe.
5) Recreate the WiFi profile on the computer, inputting the new password.
That's it.
Sorry for the long-winded note, but hopefully this helps a lot of people.