It sounds like you have a broken bios that looks at the MBR and refuses
to boot it when it doesn't like it, and it doesn't seem to like the new
version of grub.
Could you capture the MBR of both the working and non working MBR with
sudo dd if=/dev/sdb count=1 | xxd?
** Changed in: grub2 (Ubuntu)
Status: New => Incomplete
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https://bugs.launchpad.net/bugs/990888
Title:
grub2 wont boot from USB any more
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