This is reminiscent of an old A2 issue that required Tier3 intervention via remote session, and an old C2 issue that was automatically resolved by firmware action as of the June 2007 release:
Firmware 5.00.68 release notes state, in the '
code:Firmware Changes and Enhancements
' section:
"
code:Automatically delete the manufacturing diagnostic file from flash memory. If present, this file could potentially use enough space that it could prevent configuration files from being saved.
"
Beyond that, we appear to be in unknown (to me, at least) territory here...