We have been seeing this problem as well. We boot from a USB device.
Originally, we were using sfdisk to partition our device. When we would install grub, it would fail to embed the stage1_5 code. Occasionally after installing grub and rebooting, the system would hang. After careful inspection of the files, we would see that the /boot/grub/stage2 file was corrupt (lots of zeroes where data should be). We have since changed to using fdisk to partition the device. This allows the grub install to successfully embed the stage1_5 code. Our failures have been reduced, but it still happens. The failures we are seeing sound very similar in that it hangs right at this point. Again, we see that our stage2 file is getting corrupt. If we replace just the /boot/grub/stage2 file and re-run the grub install, everything works again. We are not sure why or how the stage2 file is getting corrupt, but we are able to install grub and reboot sometimes 50-100 times before we see the problem creep up again. I've been trying to narrow in on the problem, but I saw this post and thought I better submit something, as it may help out with the debug process. Thanks, Tracy
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