A few comments based on my own experience.
NTFS access on a Linux-based device is always iffy, because NTFS drivers are based on reverse-engineering and guessing work. There are basically three available solutions for Linux that I am aware of:
-NTFS-3G. Considered fairly reliable, but very slow. This is what Linux distro uses, because it's open sourced
- A commercial solution from Tuexera, the makers of NTFS-3G. I haven't seen anyone use it yet, so I can't really comment on it
- Paragon. Their solution is quite fast, and maybe it's reliable on an x86, but my experiences while developing on the WDLXTV project showed me the same problem as Asus: it's unreliable, and prone to cause filesystem corruption. It could be a problem specific to their Mipsel version, who knows.
Another problem (which might explain why ext2/ext3 users also experience issues) is the fact that this router can crash quite often when running Asus's release firmwares. Combined with Paragon's lack of robustness, this probably lead to a good portion of those corruption issues.
Also, a lot of users will plainly plug/unplug, without properly unmounting (ejecting) the disk first. While this is probably not the case with people reporting issues in this forum (as it's one thing they have looked at), for some people the problem starts right there.
The file corruption probably has nothing to do with Samba. Samba merely interfaces with the filesystem drivers to do its read/write operations.
Finally, it's also possible there is a bug with the USB driver or the hardware implementation. It's unlikely, but nonetheless a possibility.
My recommendations:
1) Use ext2 or ext3. You will probably gain in performance, and definitely gain in reliability.
2) Pay attention to whether your router has a tendency to reboot itself randomly (i.e. crash). If you telnet in, run "uptime" to see how long it's been up and running. It will be obvious if your router reboots a few times per day. If that's the case, either revert to build 112, or use one of my builds (130 RM9 or newer).
3) Always use the eject function from the web interface before unplugging a disk.
For the records, I haven't encountered any corruption issue with the 4 GB flash drive I keep plugged in. But, it's formatted in ext3, and I only use the SMB part for test purposes. It's mostly used for Optware and storing development files. So if that issue only occurs in specific scenarios, that might explain why Asus hasn't run into it yet. Making them aware of the issues might get them to devote more time in testing this specific area tho.