I've got two m645 manual bodies and neither of them does this, but it sounds electrical to me. If the battery compartment ever had corrosion, it could have damaged the wires attached to the battery case, giving you intermittent contact, and since the shutter will not fire if the battery is not providing power, this is one possible source for the problem. I would at least take it in, explain the problem, and have them take a look inside to see if they can find anything. It is completely possible thet when they tested it it worked fine so they had no idea that there was an intermittent problem.
- Randy