I have nowhere near enough knowledge of the linux kernel to make any
kind of qualified statement on this - it is however, not going to stop
me from doing it anyway...

I see two possible reasons:

a) An actual vfat error (linux's vfat code)
b) Due to different usage patterns, the vfat usage triggers a (timing?) error 
in the USB code

I am hoping that somebody with more technical insight can shed some
light on this.

Can somebody else try with ext2/3 ? I can't myself, as I have no
machines affected by this.

-- 
ehci_hcd module causes I/O errors in USB 2.0 devices
https://bugs.launchpad.net/bugs/88746
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