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Any ideas do you think it may be overdriving the 4000 STB he has working at higher speed
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OK, take a step back and look at this logically...
The STB won't really care how fast the PC on the other end of the cable is, just what the network card on the other end is doing, regardless of how fast the PC is it's still the same baseband running @ 100MHz or 10MHz down a piece of cable.
Check network card and hard set the duplex and speed to 10baseT.
Do the usual checks to make sure PC is ok, AV checks, spyware checks, firewall configs, etc, etc.
At the end of the day the issue lies with the PC, STB is the same one that was running fine with the 500MHz machine, the issue is either with the network card / drivers, or a program on the PC generating traffic. Find the issue there and all should be sorted.
re: 'slowness' not v specific. Increased latency? Increased web page rendering times? Slower transfer rates on downloads?
Try using the excellent broadband speed tester to see if there are any differences between cached and uncached transfer rates (assuming caches are involved, don't think in Rochdale they are).
If there is no caching involved and the FTP probs persist check firewall configurations, and the remote site. Remember that the cable modem in the STB is a layer 2 and layer 1 device, it shouldn't really be making any difference to a layer 4 and above protocol such as FTP, and is it uploading that's the problem, this wasn't specified.
Hope this helps a bit and more info is always useful in diagnosis.