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When you say I have to format with the dashboard, do you mean file explorer? That's what I used before and it gave me this problem to start with, so I'm a little leery about doing that.
was that before you used xbpartitioner or with 32k and F:\ only (must use 64k in this case)
free space should around 690GB total
you can select 64k clusters in xbpartitioner
is it chiped or softmodded ?
chiped uses .06(all to F:\) or .67(F:\ and G:\) bios
soft uses .06 or .67 patcher
what is you setup ?
my experenice was with softmodded only
chiped bios may be a little more stable with very large HDD
it was a real pain and after a while you get so pissed you forget what the you have tried (15 or 16 heads
.06 .67 16K 32K) and once it was filled and working it stayed that way