Burn Problem with a 4GB project: "Layer 0 Exceeds"

First off this is not the usual Dual-Layer problem. I know all about Layers how they work and how to make them. Although the error I receive deals with DL my projects or nowhere near that size.
I recently had DVDSP 4 crash on me. Ever since than its been running really funny. The biggest issue I am having is that it won't allow me to burn a DVD 5. My projects usually range from 2.5GB - 4.5GB. Let me also say that DVDSP 4's Disc meter has always been a pretty good gauge as far as I am concerned. It's always been right on telling me if something was going to fit on a DVD 5 or 9.
My problem ever since the crash is that DVDSP will not allow me to burn a DVD unless the project is under 3.5GB. I have tried everything, including a Full Re-install of DVDSP. Every time I try to burn a DVD I get the following error message:
+"Formatting was not successful. Layer 0 exceeds the maximum layer size allowed. Please choose a suitable marker location that will support this condition."+
My latest project is dealing with a 4.4Gb (according to Meter) 4.32GB actually. It is impossible for me to burn a DVD because of the error message above. I can however run the project out on a Single DLT. How does that work?
Has anyone else had a problem like this? Does anyone have an suggestions?
I have checked all the obvious settings in DVDSP and all seem to be right. I can't figure this one out.

I've never had a problem burning a 4.4 disc on a DVD 5 until now. I actually went back to some of my previous project that were a DVD-5 and I am unable to burn those now too. Everything really got screwed up on that last Crash.
Yes. I am using AC3 audio.
I have not yet tried burning my DVD project through another program...but thats a good idea.
I usually burn a DVD and DLT for the replicators...but I know they prefer a DLT. What I find odd about all of this is that I am able to run out a DLT with no errors at all. It only seems to be on the DVD side.
In regards to the uninstall...I used the exact program. I am actually in the process of doing a full reinstall of FCP2 Suite.
I'll let you know how it goes. Thanks for the suggestions.
Mike A.

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