If you think it is your prefs, then find your prefs directory and rename it to prefs_old. When Maya 4.0 starts, it won't find a prefs directory and will make a brand new one with fresh prefs. If your script works, you know there is some problem in your old prefs. When doing this test, make sure you don't have pref folders around from an older version of Maya, like 3.0 prefs.
Make sure you have the correct graphics drivers installed. We had machines that were crashing when doing an extrudeFace under 4.0. Those machines had older graphics drivers that worked fine under 3.0 but caused problems under 4.0. As soon as we replaced the drivers, the 4.0 machines were fine.
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