Hey Badpolarbear,
I would assume that the image machine works perfectly otherwise they wouldn't want to use that for an image.
I know that Ghost 7.0 had some image problems with hard drives larger than 80gig?? I'm not sure of the size, but I think that size was the issue
Ghost 8.0 works real good on NTFS and not so good on some Linux builds.
I use the Sysprep from System Builder Disks (Buy 6 disks and you get a system builder disk). I've never checked to see if the 2000 Sysprep is the same as the XP Sysprep--it may NOT be. Plus Microsoft just came out with a new Sysprep for XP. Check to see that they are using the right program (especially if SP2 is involved).
I would check to see if you are using at least Ghost 8 , I am not familiar with Ghost 9. I've had issues with Ghost 7.0 and NTFS on large drives.
As a test, try ghosting the image to a 32 gig or less drive and see if it funtions ok. If it does, then we know that either Sysprep or Ghost is suspect.
P.S.
I can't believe that you are busting the machines to XP. I'm busting XP machines left and right to Windows 2000 so we can join them to the network--go figure!
Hope this is of some help, good luck