Nigel is one of the former developers of Ghost 11.x so is on first name terms with every nut and bolt in the product. He's usually pretty much on the money with his suggestions, so please let us know if this does not fix your issue.
Things can start happening for a variety of reasons - your image size is most likely bigger than before, bioses are updated, systems run faster, timings change. Any of these can push a marginal situation "over the edge".
I note you are still using PCDOS. This is rapidly running out of steam when it comes to modern SATA based hardware with big drives, and modern NIC chipsets.
If you have not explored the WinPE route yet, then I would strongly recommend spending a bit of time to get this up and running, as it will save you some hair pulling in the future.