I was having the same problem with the disk check as described in preceding messages. After playing with it for a while, I concluded the problem was not with FORMATTING but with PARTITIONING.
Apparently the flash drive I was using was partitioned as FAT32 -- then I used mke2fs or mkfs.ext2 to format it. Mount looks at the file system and sees EXT2, but "Fdisk -l" apparently just looks at the partition code and therefore reports it as FAT32.
So my fix was:
1. Pop in another USB flash drive in the second USB port,
2. Use fdisk to delete the existing partition, create a new partition, and make sure it was type 83,
3. Format it with mkfs.ext2,
4. Mount it as /tmp/mnt/NEW,
5. Use rsync to copy everything from the old drive to /tmp/mnt/NEW,
6. Umount /tmp/mnt/NEW,
7. Use tune2fs to set the label the same as my old drive's label,
8. Turn off the router,
9. Pull both drives out and put the "new" one where the "old" one was,
10. Turn on the router.
SUCCESS. Fdisk now properly reports it as "Linux", and the disk check is run at reboot.
Yes increasing to 60 is a good idea.
Now it seems like one MIGHT be able to just use Fdisk to change the partition code -- not sure if that is "destructive" to any data or not. In theory, just changing the partition type code to 83 would have fixed it, but I was uncomfortable trying that because I wasn't positive it wouldn't cause data loss.
The NEW PROBLEM: I sometimes get the "Could not start Entware", because the disk check (when not clean) takes longer than the 30 seconds allowed by the loop in services-start. It seems to take about 35 seconds. Any reason to not just change the "I=30" to "I=60" in services-start?