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Please see the following link:http://www.cisco.com/en/US/docs/wireless/access_point/1240/installation/guide/124h_f.htmlThis will allow the controller to upgrade the AP without traversing a WAN / LAN.
I've had this problem before with the 1242's. The AP's in question had older code and needed to be primed before the successfully joined the controller. Up until that point, they would show up and disappear again. TAC informed me that this was normal...