It would seem the problem resolved itself.

All our tapes are now getting full at 410GB and over. No tape is under 400GB so 
far (about 10 of them swapped around). Do not believe it was tape drive itself.

All we've done to the machine was regular ubuntu upgrades and machine restarts. 
Occasionally we would clean the drive with a cleaning tape (even when not 
asked). In addition, we ran the tapes through rewinding and weof process before 
running each nightly Full backup (did not bother to do this for Differential 
sets). 

We are happy, atleast for a moment. 
 8)

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