The exact limit is 2^32 bytes a.k.a. 4,294,967,296 bytes or 8,388,608 sectors.
To be sure to stay below the limit, you can change the geometry of the hdd, for example to
cylinders = 8322
heads = 16
blocks per track = 63
blocks per cylinder = 1008
This results in 8,388,576 sectors or 4,294,950,912 bytes.
There is
fixhddsize program on Aminet which can do this for you.
Or you can change from PFS2 to PFS2ds which allows you to use 8 GB. (To be precise, 16383 cylinders, 16 heads, 63 sectors which results in 16,514,064 sectors or 8,455,200,768 bytes).
Regarding corrupted partitions, you should upgrade to PFS3. I never had a corrupted partition with PFS3 while it happened with PFS2 every now and then.