Hi Jenifer,
I think your problem lies in teh new feature for IDS 9.40.
Prior to this version, every 'tool', except onbar has a physical limit of 2GB. The tools that were 'affected' were dbexport, onunload, unload, onstat, onmode, oncheck, ontape, ....
9.40 fixes this problem - So I think the best option you have is do a very easy migration to IDS 9.40 and every export over 2GB will work.