I had this same issues, and I had tried EVERYTHING. I finally realized after hours of discouragement that the reason my spanned clips were not working was because my hard-drive was formatted as MS-DOD FAT32, which subsequently means that the hard drive prevents clips that exceed 4gb to be processed through log and transfer. I changed my capture scratch to another hard-drive that was formatted as os-x extended journaled and everything went through just fine : ) Goodluck!
Julie Grimm
juliegrimm@myhungrycat.com