I had a problem with what has turned out to be a bad cat5 between the router and modem. . . . how, long story short, I had to switch the WPA2 from WEP. My WDS setup sees each other, but no traffic goes to the edge router. Running Tomato Firmware v1.28.7633 .3-Toastman-IPT-ND ND VPN Apologies for the subject. I hit post before finishing it and now can't seem to figure out how to edit the post title.
SOLVED--Did a 30/30/30 reset on the extension router. . . . came back with a new Wi-FI MAC address (don't ask me how/why--I thought that was physical not a virtual one presented by the firmware.) and I am not sure why I had to do this--on this one, I did clear the nvram.
I spoke too soon. Moving the router and it went back the original mac (just an unplug and re-plug) and it stopped working again. This is driving me insane. I've never had this much trouble
When it stops working, what's the WiFi MAC? After a 30/30/30 or power cycle it may be defaulting to 00:90:4C:5F:00:2A - I think that's some kind of hard-coded value in cfe.bin. Go to Advanced -> MAC address and click on "Default" for the Wireless Interface - it should change to (LAN MAC +2) where LAN MAC is the one on the bottom of the router. That's the one the other router should be expecting. I'm about to flash a test slave WRT54GL with 7633.3 (currently 7625), will post results. However my test main is an Asus RT-16N, so not exactly apples to apples.
So the problem seems to be an old one that's come back to Life. . .il0macaddr was being set to 00:90:4C:5F:00:2A. . ..problem is I forced this to the real Wireless MAC address and it changed but had no affect on WDS working. The fix was to force the wl0_hwaddr to 00:90:4C:5F:00:2A instead of the real address. This made WDS work again. I can't figure out why 00:90:4C:5F:00:2A is required/where it comes from, but I can find dozens of references to it showing up for problems on firmware over the years. I've cleared the nvram and re-flashed as well as the 30/30/30 reset. Nothing seems to make a difference. So I made an init script to reset the wl0_hwaddr to the 00:90:4C:5F:00:2A MAC from the real one.