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It is caused by geometry differences between ROM KS driver and OS4 driver. I guess ROM driver uses CHS geometry to calculate max size (C*H*S = total blocks) which is practically always smaller than actual total LBA (which is used by OS3.5+ or at least 3.9+). Only affects IDE controllers. SCSI always uses real last block.
Easiest option is to initialize the drive under WB 3.1. Or leave few unused megabytes at the end of drive.
This check is one of the main points of PFS3AIO: if block that filesystem thinks is the last block can't be read (error returned or block is outside of 4G "barrier" and TD64/NSD or Direct SCSI is not available and/or returns error): Error is shown and partition is not mounted to protect the data.
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