It can't be the data partition size, we don't have any tool that can re-partition the data partition or any other. The AIO mod and some others haven't changed anything to the data partition, only some script that places some files in other location on the data partition. And those script are located on the system partition.
I don't know why you all have this, but some do some don't. like with the recovery's. some can format the system with the build in line in the updater-script, some can't. I think there are just some small differences between the phones. But i dunno what.