Hi, I have a HD XL (TCD658000) with a failing hard drive. It started rebooting whenever we watched a certain recording. I ran a kickstart and it failed the SMART test with a Fail 7. So, I used the MFS Live CD to create a truncated image, and restored it to a WD10EURX. This worked, but videos skip frames every 2-5 minutes. This never happened with the original drive. I believe that this has to do with the 4K format of the new drive, as the MFS partitions are not aligned (base is not evenly divisible by 8.) I tried using dd to backup each partition (except for the 1st, since it's the partition table) to an image, corrected the partition alignment with pdisk by deleting and recreating the partitions, and restoring the data back from the images to each new partition. This allowed the TiVo to boot and videos played without issue. There were several problems, though... I didn't get the THX intro, TiVo Central wouldn't display, no background graphics on the Now Playing List, not all remote commands responded, videos continued to play when you hit the TiVo button, etc. I also have a regular HD (TCD652160.) As a test, I used dd to clone the original drive out of it to the WD10EURX, and used mfsinfo -x to expand the capacity. As was noted in another thread on this forum, this resulted in all MFS partitions being aligned. I didn't have the video playback problems on the HD. I'm convinced that the 4K sectors of this drive are causing the problems I'm having. Is there a source for the old 512B sector drives? Or am I going at this the wrong way? Thanks!