I am really not seeing anything obvious here. I would say you should upgrade because I do recall there were some image issues with earlier versions of vB4, but I know you don't want to do that and I honestly don't know if that would really fix the issue for you. Usually when you get an error when uploading an image, there is something in the error_logs, but you said there was not. You *may* want to try setting an upload_tmp_dir for the server, but I'm not sure if that will fix the issue either.
What about mod_security or suhosin? Are either enabled on the site? You may want to try disabling them and see if your users still have the issue.
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