Having a similar problem.

r...@zeus:~# dpkg --configure -a -D2
Setting up grub-pc (1.97~beta4-1ubuntu4) ...
D000002: fork/exec /var/lib/dpkg/info/grub-pc.postinst ( configure 
1.97~beta4-1ubuntu3 )
Installation finished. No error reported.
This is the contents of the device map /boot/grub/device.map.
Check if this is correct or not. If any of the lines is incorrect,
fix it and re-run the script `grub-install'.

(hd0)   /dev/sda
Generating grub.cfg ...
Found linux image: /boot/vmlinuz-2.6.31-14-generic
Found initrd image: /boot/initrd.img-2.6.31-14-generic
Found memtest86+ image: /boot/memtest86+.bin
Found Windows 7 (loader) on /dev/sda1
Found Mac OS X on /dev/sdb3
dpkg: error processing grub-pc (--configure):
 subprocess installed post-installation script returned error exit status 1
Errors were encountered while processing:
 grub-pc
r...@zeus:~# /var/lib/dpkg/info/grub-pc.postinst configure
Installation finished. No error reported.
This is the contents of the device map /boot/grub/device.map.
Check if this is correct or not. If any of the lines is incorrect,
fix it and re-run the script `grub-install'.

(hd0)   /dev/sda
Generating grub.cfg ...
Found linux image: /boot/vmlinuz-2.6.31-14-generic
Found initrd image: /boot/initrd.img-2.6.31-14-generic
Found memtest86+ image: /boot/memtest86+.bin
Found Windows 7 (loader) on /dev/sda1
Found Mac OS X on /dev/sdb3
r...@zeus:~# echo $?
1

So by all appearances grub-install is fine, but something is wrong in
either grub-pc.postinst or debconf/frontend causing it to return non-
zero. I'll dig deeper.

-- 
package grub-pc 1.96+20090826-3ubuntu3 failed to install/upgrade: subprocess 
installed post-installation script returned error exit status 1
https://bugs.launchpad.net/bugs/420884
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