I suggest upgrading to a more recent toolset...
Do you have the same problem with Arduino 1.0? Testing it would help isolate the changes that caused this problem to occur.For example, in Arduino 1.0.1, we added the "--relax" flag to the linker options, which helps with large programs (http://code.google.com/p/arduino/issues/detail?id=729). It's possible that the issue you're seeing is a side effect of that change, for example.
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via Egeo 16