Have you tried setting your min post count to 1 and your max to something real large, like 99999 and seeing if you still get the error?

Have you disabled ALL hacks?

I was told to do this by vb staff.

It still does not work.

Then reply to the ticket saying it still happens.

The descriptions for both settings say use 0 to disable... anyway vBulletin.com should probably be able handle your problem now. :D