Okay, the 649 files are for if you ever want to use or restore and sell that dual tuner TiVo whose drive you're about to use. The 540 files are for your lifetimed single tuner TiVo. Do you have a PC? Does it have a place to connect the older style (pre-SATA) hard drives (PATA/IDE) that are in the TiVos? Does it run Windows XP or newer? If the answer to all 3 questions is yes, go to mfslive.org and download the WinMFS program Beta build 9.3f Also download from mfslive.org the zip file of the .iso of the MFS Live cd v1.4 just to have it on hand or to use if you don't have XP or higher on that PC. Unzip the WinMFS, which will give you winmfs.exe Copy it into the Program Files folder and make yourself a shortcut to it on the desktop, unless you want to click on Start, Run and then browse for it. Also have the .tbk file on that PC where you know where it is. Hook up the 80GB drive to the PC, and boot into Windows. Do not try to find or look at the drive with any program or part of Windows. If a found new hardware balloon pops up, just click the X to close it. After Windows gets fully booted and settles down, start up WinMFS, click the "I agree to the terms" thing, and then click on "Select Drive" When the Select Drive screen/box comes up, make sure you select the 80Gb WD. It shouldn't show you the drive Windows is on, or any other drives that Windows can see. Then click on I think it's File, Restore drive or Restore image or restore something. Point it toward the 540_GSet.tbk file, do not check the don't use optimized partition layout check box, if it defaults to a swap size of 128 that's enough for an 80GB drive, then click OK or Start or whatever's on that screen. Then sit back and wait until it tells you it's done, at which point it'll probably say something like do you want to expand. Hold off on doing that for right now. If you don't have a new enough version of Windows, or a version at all, on that PC, we'll have to walk you through using 540_gset.bak with the MFS Live cd. And you won't need the original drive out of the 540 hooked to the PC for this operation.