I should have been clear that yes the 255 hard limit is the same for F3 as Oblivion, but for those that use more advanced tools (Wrye/Gary Bash) then you can extend that with mods that merge into the bashed patch.
The limit I was referring to was the limit of even bsa type files + all the allowed esp/esm files.
The point being that even though an esp is not active it is still scanned by the game engine and can contribute to instability.
So bash users can ghost the inactive and merged mods and even further extend the allowable amount.
My Oblivion game will auto crash within 2 minutes if I don't ghost the merged files because without ghosting the inactive (yet merged files) + all the mod added BSA go over the thrashing threshold amount.
Thank you for confirming that.
It isn't a conflict with any mod. I've thoroughly tested it. If I activate the first half of my mods. No issue. If I activate the second half of my mods. No issue. If I activate any combination of 140 or fewer mods. No problem. Any time I go over 140, there is a problem. Again, every mod I have has been made a master through FO3MasterUpdate, and that appears to lead to the issues.
My latest test was to create a blank.esp that contains 0 records, esmify it through garybash, activate and run the game. Problems. Ghouls who forget to wear their textures, and run around in their bare polygons. De-activate my blank.esp (which is really a master), and everything is fine.
I can only conclude from this, that most likely there is some sort of limit on master files. And that limit would appear to be 140 active master files. I'm not an expert, but that appears to be what is happening. Unfortunately I get an instant CTD if I use FO3MasterRestore on the whole load order in my latest save game. But knowing the rules will help get around them. I can merge up some similar files (armor mods, etc.), or de-master some mods that don't edit the exterior world, which is where I understand the problems come into play anyway.