Hey bill,
I guess no luck yet figuring out why a site wich uses this mod, turn completely 404 on the pages where this addon is included when someone his password is expired.
This can potentional be very damaging to your site, as everyone in the community most likely is going to have his password expire sooner or later, and when that happends, the website will appear to be completely down
If you cant find the problem, i would suggest to everyone to uninstall this addon, because it has the potential of breaking your entire site.
I really hope you can find a solution for this, or at least talk with the DEV as to why this is happening.
thanks!