Running an old MySQL 4.X and have setup Replication. The problem is that the Slave stops every time with error 1034.

Error

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caused different errors on mast er and slave. Error on master: 'Incorrect key file for table: '%-.64s'. Try to r epair it' (1034), Error on slave: 'no error' (0). Default database
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This is always happening and I suspect that could be due to the large DB (roughly around 3-6GB) with jobs doing massive deletes everyday.

Each time this happens, I reset master, stop and reset slave and dump the whole DB from master, scp to the slave and import, start slave. This sometimes causes tables to still be not in sync. Can you please advise on what is the best way for the master and slave to be in sync when this issue arises?

Possibly a 32 bit problem (2^32 = 4G). Is it a 32 bit system and/or a 32 bit install of MySQL4?

Yes. This is a 32 bit and MySQL4. Did you have the same issue?

Not specifically, but if the DB is "roughly around 3-6GB" and you do some "massive deletes", then its possible the system is at some point trying to create/access beyond 4G ie 2^32.

It's really time you used a current version of OS+MySQL ie MySQL (or MariaDB) 5.x and 64bit, otherwise you're likely to see this often.

Note that this is just a best guess based on the info provided.