Yes, the clients (appearently) read to the end of the previous file, and then sit there, while the server is writing to a new file.
I was thinking this had to do with the "unclean" shutdown of MySQL-- perhapps it's something else.
It might, but it is a bug anyway. The whole idea of replication is to be able to deal with things like unclean shutdown.
First upgrade to 4.0.18. Then if it happens again, use mysqlbinlog -j pos_at_which_the_slave_is_stuck along with od -c to gather some more details ( I suspect a truncated or corrupted binlog event), and send the details to the MySQL developers.
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