I have amd hexcore 3ghz, 8gb of ram and Windows 7 64 bit.
I’ve been working on a tool with a few subtools and last night I hit the 4gb filesize mark. I saved the tool and closed zbrush. Today when I was going to resume the work I got an error “Error has been encountered while trying to load a tool. Loading has been aborted.”
Unfortunately nothing I do seems to help at all. I tried putting zbrush in high priority in task manager, increasing my max poly setting in zbrush, turning down undo levels. Nothing works.
Is there a way to split up 4+gb files? Can I somehow export a single subtool out of the .ztl files?
Most of my backups are useless as well as they are above 4gb in size. 
I guess I’ll only work on a single subtool at any time from now on but that might cause some scaling issues, one of the reason I put all my subtools into the same tool was because I kept getting different scaled from each piece when sending it to 3dsm.