Disk utility says "keys out of order,... HD could not be repaired"

I have been trying to install osx 10.4.3 (just the update version) from the store bought kit. It fails during check of destination volume. First I found out that it was not a good idea to have 3rd party memory installed so I removed that, but no change. I have tried to repair HD using disk utility launched, at first from 10.4.3 install disk, then from original 10.3 install disk. Disk Utility now says:
Keys out of order
Rebuilding Catalogue B-tree
the volume Mac HD could not be repaired
Error: the underlying task reported failure on exit -9972
1 volume could not be repaired
Shortly after I install these 2 sticks of memory yesterday (referenced above), I was having troubles. Don't remember exactly what or what sequence, but got the locked beachball 2 or 3 times. At some point, there was a 'static' type "POP" over the speakers and maybe from the tower too but at that instant the desktop background reverted from some green apple swirls to the default blue swirls. Other than that everything continues to work perfectly fine. Static electricity is really non-existent here ; very humid, and I was carefull during install of the memory.
I made a disk image yesterday to back up selected files prior to trying to load 10.4.3 and not sure if I may have done something wrong there....
I have some 3rd party software installed like Nikon scan, Audacity, Firefox. What else do you need to know?? How do I fix the HD? How can it be messed up if everything is working normal?

It's not likely that the memory installed caused the corruption of the B-Tree, more of a coincidence that you noticed it soon after the installation. To fix a problem of that magnitude, you have two options:
1) Back up all of your important data, erase the hard drive, and reinstall everything.
2) Buy a program such as DiskWarrior to fix the B-Tree without requiring you to erase your hard drive.

Similar Messages

Disk Utility reports "keys out of order"

The machine I have is now reporting some worrying signs, when using Disk Utility it reports "keys out of order" which I have no idea what this means.
When starting in single user mode and running sbin/fsck -f it comes back with disk0s5: I/O error keys ot of order. Also its unable to repair
Bought Drive Genius and this say unable to fix and reports
error: invalid HFS resourse fork clump size in volume header (0)
HELP, what do I need to do and does anybody know what the problem is, come to to that what should I do.
Have just bought a 160GB D2 extreme hard drive firewire extreme drive as I think this might be very handy here. Assume that back up every thing is going to be essential
Thanks in advance of possible solutions
David

This is a difficult error to repair and neither Disk Utility nor fsck may be able to repair it. In which case you would need to try Disk Warrior which may have success depending upon the extent of the problem.
Boot into single-user mode and run the command, fsck -fy, at least four consecutive times but not more than seven. If fsck finally returns with a drive OK message, then it has successfully repaired the problem. If it does not succeed, then either use Disk Warrior or reformat the drive.

Invalid leaf record count, keys out of order?

Yesterday I returned home from a month long trip which I did not bring my 13 inch 2011MacBook Pro on.
I plugged it in and turned it on, and connected my phone to it so i could retrieve some photos. I looked away and looked back to see the grey "You must hard shut down your computer" error message. Possibly because i think the phone may have been disconnected without being properly ejected? So i turned it off and then later the next day, when I try to turn it on it is stuck on the white apple loading screen forever. When I startup with Command+R and enter disk utility, it tells me:
Invalid Leaf record count, keys out of order, volume could not be repaired. When I startup in single user mode and use fsck -fy it tells me the same.
I got it used less than a year ago. I have some pretty heavy applications like MS Office, Photoshop and a few other adobe applications, and The Sims 3.
Help!

When Disk Utility can't repair a hard drive, with an error like that, many buy Disk Warrior to do the repair. You can see an answer on the Disk Warrior site here.
Or, if you have a system backup, erase the hard drive (I would probably do a secure erase and write zero's to the hard drive) and restore it.

Macintosh HD can't be mounted, keys out of order and repairing can't be completed

Hi,
English isn't my mother tongue so I'll make my best to be understood.
I have a Macbook Pro from 2012, running on Yosemite (latest version). I installed Onyx which told me my disk needed to be verified and repaired. Following this advice, I restarted my computer with Disk Utility and completed a verifying and repairing. Which led to a terrible outcome. Since then, everytime I boot with my user on my Mac, my computer shuts down in the middle of the progress bar. I tried to find an explanation to it and fix it, so I tried the following things:
1) I booted with CMD + R to go into Disk Utility
2) I runned a verify Disk on "Macintosh HD" Core Storage Logical Volume Disk, which didn't give me any error
3) I unlocked "Macintosh HD" Mounted encrypted partition and runned a verify disk, which says :
"Keys out of order
The volume Macintosh HD was found corrupt and needs to be repaired.
File system check exit code is 8.
Error : the disk needs to be repaired, Repair disk."
4) Unfortunately, the "repair disk" button is grayed.
5) So I runned repair Disk on "Macintosh HD" Core Storage Logical Volume Disk, which didn't give me any error.
6) I tried to boot my computer again but it still shuts down when trying to open my user.
7) Did all the same process again, but now the error is "Keys length incorrect" and repairing is now always blocked in the middle of the progress bar.
Is there any way I could extract the data I care about (photos, etc.) before erasing the disk or buying a new one?

There's hardware and software.
Your drive could physically be in good condition but something has caused the file structure to be messed up (it just happens sometimes). The directory that keep track of files is corrupt. Disk Utility can help determine if that is the issue. In some cases it can repair the problem but it cannot do it to a drive that is being used to boot the system while you are doing that. You have to boot from another drive. Some things DU cannot repair and you need to try a stronger utility such as Diskwarrior.
A failing hard drive (one with mechanical issues) can be a cause of file structure issues but this is by no means always the case. Apart from looking at the SMART diagnosis feature of Disk Utility (and smart isn't totally reliable) there often isn't a way to tell if a drive is failing until it suddenly happens, which is why you need to maintain backups.
In your situation it does sound serious and not just minor directory corruption. You can try erasing (formatting) the drive, You may need to do this if it is really corrupt, in which case there could be underlying physical issues. I use old technology but if you have the patience you can try erasing the drive with the security option of writing zeros once (don't do more unless you are going on a 3 week vacation). This makes the drive not simply assume everything is okay by forcing it try every part of the drive by writing data. If something is gong wrong you may find it marks a lot of bad sectors, or flat out refuses to format. Then you know you need a new drive.

Unrepairable: Keys out of order

hi,
I have a MacBook Pro, a few months old, and just recently, it refused to boot. I was able to boot in single-user mode and run fsck -fy, but it gave the error "Keys out of order" and says the disk can not be repaired. I was able to boot from my install CD as well; running Disk Utility shows the hard disk as unmounted. if I click the "Mount Drive" button, the DU log says it was successful, but the disk remains grayed out. Tryign to repair the disk from DU returns the same "Keys out of order" error, and exits without repairing.
I seem to be able to start the MacBook in FW target disk mode, but it does not show up on the connected computer. Disk Utility on the connected computer gives the same behavior as from the install CD - MacBook disk is visible but grayed out, unmounted, and can not be repaired.
any suggestions? none of the repair programs work with the Intel-based Macs yet (TechTool Pro 4.5 is coming in early July, supposedly, with full support for the new architecture) - I don't like being without my MacBook for that long though. help?
many thanks,
tim d

I'll have to see if my warranty is still effective
Obviously, keep troubleshooting as you have been to see if you can repair the problem. But if your issue turns out to be a hardware problem, you are still covered. Your MacBook Pro has a one-year hardware warranty. (After 90 days, your free phone support for any issue under the sun expires - if you don't have an extended AppleCare Protection Plan - but you still have hardware warranty support and can call to get that support. More details are in this FAQ: Is phone support and warranty service free? and the links within the FAQ.)

Hard drive verification keys out of order

Following a period of very slow reponses and some screen flicker I ran disk Utility and on verifying my hard disk (a single volume) I got the message while it was checking the Catalog File saying 'keys out of order' The underlying task reported failure on exit' followed by 'the volume needs repair'. I used my system CD to try and repair the volume but got the same message. Can anyone tell me what it means and what I should do?
The machine appears to be working OK otherwise and the slow responses and flicker have sorted themselves but Disk Utility still thinks there is something wrong. I have Tech Tool pro but am a little wary of running it having heard a few horror stories.
Thanks

If you don't have a backup, do that. If you have Disk Warrior, try it, but I think TechTool Pro 4.5.1 should be fine. But always backup first.
Start using an emergency clone / system drive. Either internal (there is room for four drives after all) or FireWire (might want FW800 card and case which run as well as the ATA/100 bus).
You can always boot into single user mode (command s on startup) and at the prompt, follow the line of instructions above about typing in "sbin/fsck -fy" to fix and repair the drive. But, in a case like yours, you should be using Tiger DVD 10.4.6 and may need 3rd party utility. So I'd upgrade TTP if you have not, and buy some disk drives.
But, I would never "it seems to be working" assume that it is or that it won't get worse - it pretty much has to get worse.
Throw out what you don't need, remove what you have backed up, remove cache folders, and make sure you have at least 20% free space.
My guess, with TTP4 and people having problems, it is rare, they didn't have a backup. DW seems to be - in over 6 yrs of use, the safest. It does one thing, and the only time it has trouble is the drive doesn't have room to write a new repaired directory, or it takes too long to scavange a drive.

Keys out of order -- follow up to earlier post

I ran the install disc Disc Utility Test and the Hardware Test disc on the computer since I posted my first question earlier tonight "Computer won't finish start-up -- any suggestions". The Hardware Test came back fine. The Disc Utility test on the install disc says: Keys out of order. It does not, however, explain how to repair this problem on the hard drive.
Is there any way to fix this problem on the hard drive?
Power Mac G4 Quicksilver Mac OS X (10.3.9)

Invest in DiskWarrior. I had the same problem and DiskWarrior fixed it. No other utility programs worked for this problem. DiskWarrior is very inexpensive. Ordered online in the afternoon. It was delivered to my office the NEXT morning.

IMac won't launch, disk utility says I cannot repair my Macintosh HD, back up files, reformat the disk and restore backed up files. How do I do all that? Help!

iMac won't start up, disk utility tried to repair disk it shows "keys out of order" error message in red and advises me to back up files, reformat disk and restore backed up files. I have no idea how to back up and restore etc... Help! Please!

Get an external drive of sufficient capacity to hold everything on your internal drive.
Partition and format the external drive.
Drive Partition and Format
1. Open Disk Utility in your Utilities folder.
2. After DU loads select your hard drive (this is the entry with the mfgr.'s ID and size) from the left side list. Click on the Partition tab in the DU main window.
3. Under the Volume Scheme heading set the number of partitions from the drop down menu to one. Click on the Options button, set the partition scheme to GUID then click on the OK button. Set the format type to Mac OS Extended (Journaled.) Click on the Apply button and wait until the process has completed.
4. Select the volume you just created (this is the sub-entry under the drive entry) from the left side list. Click on the Erase tab in the DU main window.
5. Set the format type to Mac OS Extended (Journaled.) Click on the Security button, check the button for Zero Data and click on OK to return to the Erase window.
6. Click on the Erase button. The format process can take up to several hours depending upon the drive size.
Clone your internal drive to the external drive.
Clone Mavericks, Lion/Mountain Lion using Restore Option of Disk Utility
Boot to the Recovery HD:
Restart the computer and after the chime press and hold down the COMMAND and R keys until the menu screen appears. Alternatively, restart the computer and after the chime press and hold down the OPTION key until the boot manager screen appears. Select the Recovery HD and click on the downward pointing arrow button.
     1. Select Disk Utility from the main menu then press the Continue
         button.
     2. Select the destination volume from the left side list.
     3. Click on the Restore tab in the DU main window.
     4. Select the destination volume from the left side list and drag it
         to the Destination entry field.
     5. Select the source volume from the left side list and drag it to
         the Source entry field.
     6. Double-check you got it right, then click on the Restore button.
Destination means the external backup drive. Source means the internal startup drive.
Boot from the external drive.
Boot Using OPTION key:
1. Restart the computer.
2. Immediately after the chime press and hold down the
      "OPTION" key.
3. Release the key when the boot manager appears.
4. Select the external disk icon from which you want to boot.
5. Click on the arrow button below the icon.
Reformat the internal drive and install OS X.
Install or Reinstall Mavericks, Lion/Mountain Lion from Scratch
Boot to the Recovery HD:
Restart the computer and after the chime press and hold down the COMMAND and R keys until the menu screen appears. Alternatively, restart the computer and after the chime press and hold down the OPTION key until the boot manager screen appears. Select the Recovery HD and click on the downward pointing arrow button.
Erase the hard drive:
1. Select Disk Utility from the main menu and click on the Continue button.
2. After DU loads select your startup volume (usually Macintosh HD) from the
      left side list. Click on the Erase tab in the DU main window.
3. Set the format type to Mac OS Extended (Journaled.) Optionally, click on
      the Security button and set the Zero Data option to one-pass. Click on
      the Erase button and wait until the process has completed.
4. Quit DU and return to the main menu.
Reinstall Lion/Mountain Lion, Mavericks: Select Reinstall Lion/Mountain Lion, Mavericks and click on the Install button.
Note: You will need an active Internet connection. I suggest using Ethernet if possible
            because it is three times faster than wireless.
Open Startup Disk preferences and set the internal drive as the startup volume, then click on the Restart button.
Restore your data from your external drive backup.

Grey screen, keys out of order

Hello and ...help, hard drive problems!!
My iMac G4 with 10.2.8 was acting strangely - Word & Excel wouldn't work, long spinning beach ball. Upon restarting got stuck at the grey screen with the spinning cog. I have tried a variety of suggested fixes without success. Using disk utility ended with messages such as "disk not mounted" and "keys out of order" in red print. Repair completed was indicated but no joy with startup. Started in Single user mode, tried fsck - same "keys out of order"(4, 3140) & Volume can not be repaired.
When starting with a firewire link to my iBook the message was "you have inserted a disk containing no volumes that MacOX can read. Am i looking at a. Full reintitialising or
b. a new hard drive
Is there a way to retrieve any files??
Thanks in advance
Geoff

I don't know if Disk Warrior will cure all your problems but it is known to fix "keys out of order" problems and to rescue hard drives that seem impossible to fix.
Here is more information about this program:
http://www.versiontracker.com/dyn/moreinfo/macosx/19441
So I would certainly try that first. It is a great utility to have around so would not be a waste of money even if you do have to replace your hard drive.
If you don't get your hard drive running again the only way to get your files is from a disk retrival place which is very expensive.
Renae

I have an iMac mid 2010. After Disk utilities said the drive was corrupt, I ran the hardware test (extended) 3 times. No problems. I than ran Disk utility again and got 2 messages in red-keys out of order, and --Volume corrupt, can't be repaired. I tried

I have an iMac mid 2010. After Disk utilities said the drive was corrupt, I ran the hardware test (extended) 3 times. No problems. I than ran Disk utility again and got 2 messages in red…keys out of order, and ……Volume corrupt, can't be repaired.
I tried to do a system install, but message said…disk can't be changed. Will a complete erase and install fix this ?
Everything is backed-up.

There's hardware and software.
Your drive could physically be in good condition but something has caused the file structure to be messed up (it just happens sometimes). The directory that keep track of files is corrupt. Disk Utility can help determine if that is the issue. In some cases it can repair the problem but it cannot do it to a drive that is being used to boot the system while you are doing that. You have to boot from another drive. Some things DU cannot repair and you need to try a stronger utility such as Diskwarrior.
A failing hard drive (one with mechanical issues) can be a cause of file structure issues but this is by no means always the case. Apart from looking at the SMART diagnosis feature of Disk Utility (and smart isn't totally reliable) there often isn't a way to tell if a drive is failing until it suddenly happens, which is why you need to maintain backups.
In your situation it does sound serious and not just minor directory corruption. You can try erasing (formatting) the drive, You may need to do this if it is really corrupt, in which case there could be underlying physical issues. I use old technology but if you have the patience you can try erasing the drive with the security option of writing zeros once (don't do more unless you are going on a 3 week vacation). This makes the drive not simply assume everything is okay by forcing it try every part of the drive by writing data. If something is gong wrong you may find it marks a lot of bad sectors, or flat out refuses to format. Then you know you need a new drive.

"Keys out of order" message in Disk Utility

Hi,
I was just doing a regular maintenance check with Onyx and to my surprise it said I needed to repair the disk using the Installer DVD and Disk Utility.
I did this and again to my surprise I seem to have a problem.
After the whole processs is complete these messages come up:
"keys out of order" (in red)
1 HFS Volume repaired (in green)
1 Volume could not be repaired (in red)
I don't know what to do about this. On the one hand my system seems to be running fine, but on the other if these errors are coming up then surely there is an issue which I need to resolve.
Could someone enlighten me on what to do next?

Hi,
Thanks. Unfortunately my battey died and now I am stuck on the apple logo at reboot. Opening disk utility via the install disk doesn't work as disk utils doesn't recognise any disks (even though I hear them spinning)
I am lucky in that I am able to access th powerbook's HD in target mode via firewire on my G5
so I am going to copy over a lot of my data and then invest in Diskwarrior.
However, I am a little confused with the Diskwarrior website. I would prefer to download as I am not near a shop to buy the software and I would rather not pay for express amazon delivery.
Would I be able to use the download of diskwarrior on my Powerbook?
It seems a little confusing:
"If You Are Purchasing DiskWarrior
Repairing your usual startup disk requires that you start up from another disk. In order to use the download copy of DiskWarrior, you will need to start up from another disk with Mac OS X 10.3.9 through 10.4.x installed. You will then need to run a copy of DiskWarrior from a disk that is not the disk you are repairing. (The DiskWarrior download does not include the Apple System files necessary to create a startup CD.) If you cannot use the download version of the software (i.e. you have only one internal hard drive and this is the drive you wish to repair), please order directly from our sales department or from one of our resellers to be sent the software on CD. If you order via the secure server, you will be sent a CD, but delivery of your CD will take approximately three to four weeks, depending on your location."
Basically I am in a hurry to get my Powerbook working by Thursday my two options are
a)Buy from Amazon and pay extra to get express delivery by wednesday
b)Buy download from Alsoft (with cd version on way in 2-3 weeks)....however if the download version is not sufficient then i'm screwed.
I'd really appreciate help here. It just happens that I have to work away on Thursday....and I therefore need my powerbook. I usually use my G5 in my home studio.
THANKS!!
Message was edited by: recall

Keys out of order, disk utility fails

PowerPC (?, whatever came just before Intel-based machines) iMac running 10.3.something failed to boot - hangs at "Logging into OSX" window but never gets there to log in. Booting from Install CR-ROM and running Disk Utility fails to repair Catalog. Booting in single user mode results in "Keys out of order (4, 51882)" "The volume Macintosh HD could not be repaired". Also tried to boot from Prosoft "Data Rescue II" CD-ROM but no help
Any suggestions to repair/recover?
Files all appear to be there - can navigate around in Unix and list them. Also have external Lacie hard drives connected (unconnecting does not resolve problem) - Would there be a way to cp or rcp some key files to these external drives to at least recover some?

Welcome To  Discussions jeff_st!
If all else fails, and you have access to another Firewire enabled Mac, you can also use Firewire Target Disk Mode, to backup as much data as possible.
Then reformat the HD, zeroing all data, and perform an Erase & Install.
ali b

10.4.10 'Keys out of order' - unable to repair disk!!

After getting sick and tired of endless problems with my 3 month old iMac, which only seem to get worse with every update, I've just run the Disk Utility. It found many problems with permissions and sorted those out. So then I thought I'd just verify the disk to make sure and got this....
Verifying volume “Macintosh HD”
Checking HFS Plus volume.
Checking Extents Overflow file.
Checking Catalog file.
Keys out of order
The volume Macintosh HD needs to be repaired.
Error: The underlying task reported failure on exit
1 HFS volume checked
Volume needs repair
But no, it can't repair the disk.... Help!

I have to say I bitterly regret switching to Macs
- very expensive, unstable, and clearly susceptible
to fundamental problems like this.
All modern computers are susceptible to this sort of problem (file system corruption) -- that's why it is a fundamental problem. If you want to avoid the possibility, you have to avoid using a file-based OS, which limits you to OS's embedded in ROM ... like maybe a 30 year old Commodore 64.
Seriously, if you want to protect yourself from this sort of problem -- no matter what OS you use -- there is only one reliable option: backup your files regularly to something other than your startup drive.

Keys out of order - reinstalling OS X or get Disk Warrior - Advice?

My nightmare is below but before describing it, I'm at this point in the problem: using an IBM laptop I've already logged into my 800MHz Mac G4 using Target mode and extracted all important files using HFS Explorer. Now I need help on what to do next so that I can try to save myself from having to reformat the Mac's hard drive. The full story:
I ran 5 Apple software updates (listed below with approximate versions from my recollection) and the Mac installed them fine but rebooted to a blank blue screen. The OS level before running these updates was v.10.4.10 ...
Apple OS X version 10.4.11 update
QuickTime v. 7.5.1
Java Console update
iTunes 8.0.1
…and one other minor update program.
... after several reboots I found that the Mac was pretty much gone. The error message I got in verbose mode was: "keys out of order, (4, 726)". I started the Mac in Single User Mode and ran several variants of the fsck command (-y, -fy, etc.) about 4 times each and no dice - the message I always got was: "Rebuilding catalog B-tree"... followed by: "volume could not be repaired". The Mac will not boot from the Mac OS X CD and I already tried holding down the "C" key trick but no dice there either. The only thing I haven't tried yet is typing "boot cdrom" at the Apple Firmware prompt - and wanted to ask if anyone thinks this might actually boot the OS X CD (?)
At this point my real question is how to preserve the programs & files on the Mac and get it back working, if possible, without having to reformat the hard drive. I did not purchase Disk Warrior because the Mac won't boot the OS X CD using the "C" key. The Mac will eject the CD tray and I can insert the OS X CD but the CD never spins up and the Mac spits the CD out and then shuts itself down. If the "boot cdrom" command will work in the Firmware, then purchasing Disk Warrior becomes an option. I see my options right now as the following. Anyone know which option is best to reduce the headache factor and save the wallet.
1. If "boot cdrom" using Apple Firmware will in fact boot a CD, will using Disk Warrior preserve the Mac's installed programs (Adobe Suite CS2) once Disk Warrior creates the new hard drive volume?
2. Use "boot cdrom" using Apple Firmware and re-install OS X (will Adobe Suite still be installed?) Yes, it's a legal copy of CS2 but the install CD is not at my house and will take a week to get.
3. Reformat the hard drive, install OS X and reinstall Adobe Suite, reconfigure my wireless settings, etc. and all the other stuff you have to do after a hard drive has to be reformatted.
4. Take it to the local Apple Store
5. ??? Any other options out there ???
Thanks in advance.
RPQ

Thank you for the replies. Here is the final outcome on this one: a bad hard drive. The verdict from a local Apple authorized service center was that it was a coincidence that the hard drive (made in 2001) pretty much failed at the point when I was running the 5 updates. On their test bench, my Mac would not boot from the OS X CD or a DiskWarrior CD, but, it would boot from an external hard drive. I was told the CD-ROM drive and hard drive are on separate buses so the service provider did some testing with a new hard drive and the old hard drive. They were straight with me and everything they tried made sense because they were the same problems that I encountered when trying to fix/diagnose the Mac. In the end, they installed a new 250GB hard drive, installed OS 10.4.6 and gave me the old hard drive back – on which I still can access all the old files just in case I missed any with my original copy job to my laptop using HFS Explorer. $169 total bill. Not bad.
I still think there is probably a way to clone the old hard drive but that could have run up the labor charges and by that time I could have purchased another entire (used) G4. So the only real loss is not having the Adobe CS2 suite of programs installed but I can still get the install disk if needed. Now sitting in my update list is: the Apple update to OS 10.4.11… the minimum OS system requirement to get a brand new Nano to work on a Mac. My fear is that running that update might cause the same Keys out of Order issue on this ol’ Mac so I’m thinking that I’m not going to install any more updates – just in case!

Weird "keys out of order" problem

So, keys out of order was new to me, but I've read up about possible fixes... My situation seems strange, here's why...
I was working on my dual 1.8 G5, 10.4.11, clicked on a video link, then got the greyed out screen, and the multilingual restart message.
So, I did several restarts, but the fans would go to full, and it would shut down before showing any activity on screen. So I entered single user mode, and typed the command for checking the disk (thankfully I could get info from the web on my macbook). That's when the 'keys out of order' message was first seen. After reading up I tried to run the fsck thing, which I read could be an option. I got an 'unable to repair' message. Then I put my workmates machine into target disk mode and started from that disk and tried to run disk utility over my startup disk, of course it didn't work, with several warnings in read about keys out of order etc.
So I'm learning that DiskWarior is probably my best bet, but in the meantime I put my machine in target disk mode, and using a handy hint I found online, dsragged out my g3 iMac, booted it into OS9, extensions off. Connected by firewire, my G5 HD showed up and I was able to drag off some recent files, Mail folder etc. (At this point let me say I did a system back to a DMG file on a separate partition of an external USB drive several months ago, and that maybe 99% of my work and important files are on another external drive, so it's not life and death here.)
NOW... comes the strange part. I go back to my machine, and just for a lark try to start it up again.... and it starts up fine, no problems, everything normal. Wow I think, I'll go and run disk utility over it now, so I restart using my friends powermac, and run said program, and get exactly the same errors, keys out of order. hmmm.
So I go back to my machine, restart using its own system, all good, all fine. So I plug in another external HD and do a clone of the internal drive while its all working fine.
So, since then its been running fine, (about a day and a half). But what should I do, and what's going on? Should I reformat my drive and out the earlier cloned system on it? Would the recent system clone I did likely be corrupt? Does it seem right that my system should work OK now, when Disk Utility was still reporting keys out of order? Should I pony up and buy DiskWarrior? (can't really afford to to be honest)
I'm a bit flummoxed, thanks for any help...

Hi, weird but not completely inexplicable.
Indeed Disk Warrior is your best bet, IMHO every Mac oener should have it.
I wouldn't completely trust any clone/backup once you get that error.
Generally the only real fix for that error is DW, or Zeroing your drive & reinstalling.
http://supportdb.alsoft.com:591/FMPro?-db=alsoftsupport&-lay=main&-max=15&-forma t=AlsoftSupport-qa.html&-script=counter&-token=182&-Skip=101&-find

Disk utility says "keys out of order,... HD could not be repaired"

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