> >>> I've tried an old 'bypass': sysctl kern.geom.debugflags=16, but 
> >>> that
>  >>> didn't help.
>  >>>
>  >>> Can anyone help me get this new disk installed without having to 
> boot  >>> off a recovery CD? The server is 500 miles away from me and 
> I don't  >>> have direct console access.
>  >>>
>  >>
>  >> Uhmm... This may seem silly, but did you use fdisk to create a 
> slice  >> first before you tried partitioning?
>  >>
>  >this is NOT needed. actually i don't do it anywhere.
>  >
>  >it just may be sysinstall problem, anything else.
>
>
> I tried using fdisk first, same problem, won't let me write to the disk.

Do you will use the entire disk in one partition ? If so, just do:
newfs /dev/ad4

Maybe you should to use gjournal for this large filesystem....

------------

I tried newfs before, same issue:

# newfs /dev/ad4
newfs: /dev/ad4: failed to open disk for writing

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