Unfortunately this is not just a cosmetic bug with ML Disk Utility. This issue occurred for me after attempting to clone my startup volume to a new WD 2.5" 500GB HDD. The clone was successful but due to the "Partition map repair failed while adjusting structures to fit current whole disk size" bug, my MacBook Pro wouldn't start up from the new WD disk once I installed it internally due to the partition map having become corrupted. Neither the GUID or Recovery partitions were able to be seen by my MBP -- only a corrupted Master Boot Record partition that could neither be verified or repaired.
Here are the details:
The drive is a brand new 500GB Western Digital Black WD500BPKT installed on my Late 2008 MacBook Pro running Mountain Lion 10.8.2.
Here's what happened:
- Used a new Rosewill SATA to USB adapter to connect the drive to the computer. (I'm not happy with the Rosewill adapter which, if moved, will disconnect the drive. It is being returned.)
- Formatted the drive as Mac OS Extended (Journaled) with one GUID partition.
- Scanned the drive for bad blocks and ran integrity test with Drive Genius. (Passed both tests.)
- Cloned my startup drive to the new WD drive using Carbon Copy Cloner with no issues. (CCC created a ML Recovery Partition using CCC with no issues.)
- Shut down the computer while the WD was connected via the SATA USB adapter.
- Installed the WD drive in the MacBook Pro.
The MacBook Pro would not see the WD cloned startup volume or the cloned Recover Volume, only a small Master Boot Record partition. I was able to use my original HDD's Recovery Partition (connected via the SATA USB adapter) in order to use Disk Utility to investigate the issue I was experiencing with the WD disk. Disk Utility reported only a Master Boot Record partition that could not be Verified or Repaired.
I then:
- Reinstalled my original hard drive into the MacBook Pro, which then booted normally.
- Connected the WD to my computer using the SATA USB adapter.
- Ran Disk Utility and received this error when trying to verify the MBR: "Partition map repair failed while adjusting structures to fit current whole disk size." (There seem to be a few Apple Discussions regarding an issue that may be causing partition map corruption with some external disks that involvers having the drives connected while Mountain Lion sleeps or wakes from sleep.)
- I then re-formatted the WD disk using Disk Utility. (Mac OS Extended (Journaled) with one GUID partition. Successfully formatted.)
- Verified the MBR partition. (It verified successfully.)
Now here's the kicker:
- I put my Mac to sleep with the WD disk still attached via the SATA USB adapter.
- Woke up the MacBook Pro and the WD appeared on the Desktop and in Disk Utility normally.
- Re-Verified the partition map partition and -- guess what -- received the following error: Partition map repair failed while adjusting structures to fit current whole disk size."
So it seems that under some circumstances, with some disks, Mountain Lion and Sleep may indeed corrupt the partition map.