Clearly sounds like you've got a corrupted flash in that unit. I believe the 4400s had an actual CF module that was removable but you had to open the unit up. Since they're just booting linux off of the flash modules, your best bet is to try and get a working 4400 and try to dd the flash from the good unit onto the flash from the bad unit. There has been reported success with performing this operation on a NM unit (and I've heard of success with a 2100) and someone wrote a good blog about it at: http://sc-wifi.com/2011/05/30/resurrecting-a-bricked-nm-air-wlc6/
Good luck and let us know how it goes! -Sam
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