New
#31
I think there are still two keys in the registry that control mounted storage devices. I think what may have happened is that the key that records the disk "signature" and the key that relates the drive letter to the appropriate "signature" got discombobulated. So he could assign a letter when it was running, and it would stick, but not written to the registry because of the disconnect between the two keys. So after a reboot he'd have lost his drive letter all over again.
So when the the disk's MBR/PBR is overwritten with zeroes, and then Windows sees it, it thinks "new disk" and rewrites the correct data to those two keys in the registry. Now the info in each registry key properly corresponds with each other and he can assign a letter which will stick across reboots. And the more I think about it, the more I think that all that was necessary to fix it would be to delete the one or both of the keys that correspond with that disk. But, without seeing the registry before/after it would be hard for me to say for sure.
I don't think there was any corruption of the MBR/PBR that caused this, or anything wrong at all with the drive, as a drive has no idea what drive letter has been assigned to its partitions. If there was something wrong with the MBR/PBR, he would have had problems beyond the assigning of drive letters.
And yes, agree with you that he would've lost all data on the disk. Unless he used recovery software to get the data within the first and last million sectors. But I think you had given plenty of warning.