In my experience, the party window when I'm in an explorable zone and the party window in a town are unrelated as to size. I could have just been playing Venta Cemetery, had the window sized up to hold all the NPCs, and when I go back in the window is small again. Next time I go out, it's large again.
I've also seen it resize itself, usually when people invite into a group. There could be plenty of room at the bottom of the window to hold the invite section, but it tacks it onto the bottom, shooting the window size up.
Finally, I've seen sometimes (usually when adding heroes/henchmen) the scroll bar appearing at around 5 members, and then disappearing when I add the next member. The scroll bar isn't needed; the party window is larger than the group.
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