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Dave, why not use a switching regulator like LM2576-5.0, and nip these problems in the bud?
My unit's regulator gets warm, and I have not seen how far cooked it becomes when I run with full backlight in the night, but I have not noticed any toasty smell or other signs that is acting up. But fixing issues one by one like the use of a switching regulator would solve issues one by one, particularly for folks that simply buy the unit and plonk it on the dash.
I know that was not the intention to begin with, but now making some such arrangements is really a form of public service. Wotsay?
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