Wow I though I would have an e-mail if someone replied. So I totally forgot to check back!. But I fixed it a while ago! How? Not sure.
First off, I have a ASUS A8V-VM. Its a cheap socket 939 VIA chipset motherboard.
I first tested the 80GB SATA harddrive with pfsense in another machine. Booted with no problem.
Put back into my router box, no go.
reset cmos on the motherboard just 'cause, no go.
I reset all my cmos settings, like date,time,turn off serial port etc. Until i got the SATA controller settings. I didn't remember if I had it in SATA or RAID mode, or RAID with BOOTROM. So I left it in SATA mode, No go.
Okay frustrated, I tried RAID mode with bootrom off, no go.
Bootrom on, booted. Bootrom shows with a large yellow warning about unix file system detected. So I continue.
It worked!. Still today I don't understand the yellow warning.
To my memory I never had RAID enabled in bios ever. I was running this box for 8-10 months before this happened one day.
It been running great ever since.
Why this fixed it? I don't know. I'm more of a Power user than an advance user.
But if anyone has this problem. They should 'fiddle' with their drive controller setting?
Or try an IDE drive over SATA for testing?