James -
if your processor was programmed by an audiologist once it's returned from Cochlear you need to get an audiologist to reprogram it.
I'm one of those lucky enough to have "factory settings", so when I have to send my processor in for repairs (only done twice) I can wear it without programming.
The cost of programming and reprogramming depends on the facility you go to; some places charge, some places don't.
My doc's office doesn't charge anything for the initial programming. I'm not sure about subsequent programming though, since I've never needed it.
Dale -
all I can say is - although it's a pain - if Cochlear can't fix your processor to your satisfaction they will give you a new one. Insist on this - even if you have to get 2 or 3 new ones. As with other things, sometimes there are "lemons" that just can't be fixed.
Jan