YouTube is doing some form of foot printing on files looking for duplicate content (video/audio).
If you need to reuse a video, you will need do something to each copy of the video to make it unique. Is there a specific percent difference that they are looking for to have changed?, yes probably, but I wouldn't suggest focus on that. Instead, change something on each video that will both modify the video, and help better inform users.For example, modifying the opening and closing titles of the video to better match the specific circumstance under which you are reusing that video. On a side note, there is good info on adding captions and subtitles here: http://www.google.com/support/youtube/bin/answer.py?answer=100077
