[Gumpy]

You said you are deleting the game.Are you going into the program files and deleting the game folder that gets left behind after you delete?you must do this because, there may be a corrupt file in that left over game folder that will mess up any new install.Did you install the 4.08m patch first?From another post
The 5% crash is usually a missing or corrupt .SFS file. It can happen if you install a sound mod, mod activator, or unified installer, without first patching the game to 4.08m.Also did you get your game from here direct2drive.com?You may need this (The link is inoperative)