Since your upgrade worked fine on a machine with 4GB, and I'm sure others have had no problems upgrading on a machine with less than 2TB, I'd be curious to see what the *cfg file looks like.
Has anyone made any recent manual changes to the *cfg file (eg, entered a value they thought was 'number of bytes' but is interpreted as 'number of 2k pages'?
I'd also want to rule out any sort of corruption of the *cfg file.