I like how you didn't actually tell us what your card's model & chipset actually is. Anyway, if you happen to have an atheros based card (which, given you mentioning the 3 hardware versions, you may well have), this may help you.
Before I bought my card (CARDBUS D-Link AirPlus DWL-G650, Atheros chipset, hardware revision C3), I looked at plenty of forums and noted that the madwifi (Multiband Atheros Drivers for WIFI - www.madwifi.org) drivers had recieved mixed results from various people, notably the third (C) major revision didn't work yet. I figured I'd risk it, figured that even if it didn't work yet it would within the next few months. Anyway, I got the card home, checked out the latest CVS,
$ make
$ su
# make install
# modprobe ath-pci
# iwconfig ath0 essid my_ssid
whatever else you need to set on the card
# ifconfig ath0 up
Worked first go (though, at that time the drivers were not quite stable with my card revision, good thing I was with Slackware 10.0 (I've noted my success/failures with various distros below). As of sometime late sep/early oct those issues were fixed.)
There are now 2 branches of madwifi, old and ng. Old will often work with most distros without having to modify their scripts, ng may need to, check the wiki at madwifi.org for help. Currently both branches have features missing from the other, when it's finally released, ng will have everything. I have also noticed that ng takes 30 seconds to associate with my AP (Using WPA-PSK, AES), whereas old only takes a few seconds (Also annoying as it needs to re associate everytime the key changes, so I'm currently using old).
For WPA support, you need the wpa_supplicant program (make sure you get at least 0.4.7 to work with ng, at least 0.4.6 to work with old). Deffinately read through the README and INSTALL files compiling from source - you need to copy defconfig to .config and edit it for your particular setup before you can start compiling.
***** Successful distros
* Slackware 10.0 - no problems, I always called the commands directly, but if you want ease of use, apparently the scripts need to be modified for ng but not old.
* Debian 3.1 (Current) - no problems (had to compile the latest madwifi-ng and wpa_supplicant from source. Friend had troubles with wpa_supplicant - repositories didn't have latest version for ng yet, and he had some trouble compiling from source, I think he just didn't install the required -dev packages for openssl, etc)
* Auditor (can't think of the version number, think it's still the latest) - came with drivers that worked like a charm :) No crashes or anything
***** 1 Success, 1 Failure
* SuSE 10.0 Eval - Comes with madwifi drivers checked out before those stability issues with the latest revision were worked out. I had major dramas after compiling from source (NEED to get SUSEBuild script from the madwifi wiki to even attempt it), tried several snapshots, including ones I knew worked, kept getting "The hardware didn't respond as expected". I had other hardware issues with SuSE as well (I don't think it liked my laptop very much), so I gave up. On the other hand, my friend had no issues with it at all, using the drivers it came with (Only eval/bought CDs come with madwifi, OSS CDs do not, if you have them, you'll need to download the non-gpl kernel package from the repository).
***** Failures
* Mandrake 10.1 - Personally didn't try, my friend couldn't get his working.
* Ubuntu - personally didn't try, friend had no luck.
Hope this helps you or at least someone