Hi,

I unfortunately can't answer to all your questions, but a few ones:
I ignored that 'internal' use was to be desupported... are you sure of this ?

- A password file is created automatically when you use 816 database config assistant, otherwise, if you create your database manually, and want a password file, you must use the command "orapwd" (type orapwd /? under a dos prompt for an explanation on how to use it...)

- If a password file is deleted, you must create another one, and make the grants again...
- There should be only one pwd per server, which will be used for any database of this server...

- You can't just rename the passord file, but if you wish to move it another place, or rename it anyway, you have 2 solutions:
1- delete the file, create another one (orapwd) and grant your privileged users again.
2- make a copy of your pwd file, delete it, then create another one with orapwd (new name, new place), and then rename the copy of your 'old' pwd file to the new one.
WARNING though: under UNIX OS, I was always unable to create a pwd file with name other than the default, and was unable too to locate it another place. I don't know under NT, as we don't use pwd files anyway...

Hope it helps! (and forgive my late answer..)

Cheers

Fabien