'mkfs.ext2: command not found'
I'm wondering if this can be installed from one of the packages ?
in e2fsprogs?
Disclaimer: I don't know exactly how all this work so what I say might not be correct...
The 5500 is not the same beast at the other zaurus, I'm not sure that "resizing the root partition" makes sense on a 5500 because of the very small flash and because part (all) of the os is in the ram. (As I don't own a 5500 I don't know the exact details, where does / resides?)
Maybe it's possible to do a pivot root on a sd card or cf card like it's done for the C3000?
In any case I don't think it's something trivial (like you proably need another image).
Maybe you should try to pm VoiDeR on this forum, there is a kernel configuration for other rom to have all the system on a card and he was asking for it, maybe he has done or found something like this?