Thanks to everyone helping out here!
Based on the fix of reedpi's problem I seem to have found a MUCH easier way that I want to share:
I had the same problem and his solution did work, but it required a reinstall of 10.7.4. and the installing of a developers driver, which has never been officially released by NVIDIA. (This is probably the reason I got a red warning to update in my CUDA preference pane.)
The solution in short:
I BOOTED IN 64-bit mode and can now use the latest drivers from NVIDIA without problems!
(This was mentioned somewhere in the thread, but it really was the solution)
Just download the latest CUDA and NVIDIA graphics drivers and CS6 will recognize the CUDA-GPU as advertised!
The long story:
The previous solution was:
CUDA Driver Version: 4.0.21
GPU Driver Version: 7.18.18 270.05.25f01 (seems only available if 10.7.4. is reinstalled)
I was going through the drivers archive (at http://www.nvidia.com/object/mac-driver-archive.html ) and noticed that starting with Driver 4.0.31, NVIDIA states:
"Prior to the CUDA 4.0.31 Mac drivers, when running a 64-bit application with the OS configured as 32-bit kernel, the application may crash. This update will resolve that issue"
This meant on MacPro4,1, which by default seems to boot in 32-bit, there was a difference in the way the driver booted It also explained why all previous versions worked fine.
You need to boot into 64-bit in order for the current drivers to work. (You boot into 32-bit or 64-bit mode by holding the keys 3-2 or 6-4 during boot. A 32-bit boot will show up like this: see About This Mac -> System Report -> Software: 64-bit Kernel and Extensions: No)
Then Mercury Playback Engine and After Effects CS6 will "see" your Quadro-Card even when running the latest CUDA Driver (currently 4.2.10).
Here's the good part: You can up- and/or downgrade CUDA Drivers and go between versions. You don't need to reboot between launching CS6 AfterEffects or Premiere Pro. You don't need to uninstall before installing. It's easy to test.
So now I'm running the latest versions:
CUDA Driver Version: 4.2.10
GPU Driver Version: 1.3.4.0 (270.00.00f06)
When I rechecked, the behavior was consistent with my previous observations:
if 64-bit Kernel and Extensions: No (32-bit default boot)
-> Premiere Pro CS6 & After Effects don't support the GPU. Error message when launching After Effects.
if 64-bit Kernel and Extensions: Yes (64-bit boot)
CS6 GPU Acceleration works as advertised
For more Info about 32- or 64-bit booting from Apple go here: OS X: Starting up with the 32-bit or 64-bit kernel
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