Hi,
I think, I was able to reproduce that problem ...
The problem might be
post_max_size = ??? in php.ini.
As soon as the posted data exceeds the value set here, $POST and $REQUEST were empty (besides the PHPSESSION info since I have session.auto_start on I think. But all data that came from the form disappeared.
When I set the value to a higher value than the size of the POST data to be expected from the form it worked.
The bad thing about this is that even if you set error_reporting to E_ALL not even a warning appears.
Thomas