UPDATE
Well, I did the swap to my Ti4200 card and installed the latest ForceWare 77.77. Game works like a charm now. Been playing for the last 4-5 hours and there are no BSODs, 1/3 load problems, movie problems, etc...
Actually video performance with the Ti4200 isn't that bad. I'm running 1280x1024 @ 60Hz with High texture pack. Turned off shadows, AA but I have first level anisotropy on. Not as fast as my 9600XT but still playable with reasonable frame rates. I can sacrifice some graphics quality so that I can continue playing the game!
Thanks for everyone's responses.