Bad HDD sector/crashing

[AWT]

I think that my 2 drive TiVo has a bad sector. Occasionally it will lockup during play and reboot after a short period.

I could reproduce the problem at the exact same point in the recording and I've managed to undelete the problematic recording with a (reluctant) view to keeping it occupying the bad sector(s). TBH though, I'd rather fix the problem and delete the recording.
Here's the log:
Oct 8 22:05:00 (none) kernel: mediaswitch: returning 0 from standin tune after tuning to ch 0 with adjust -1
Oct 8 22:05:05 (none) kernel: IDE: calling handler with dma_running, altstat=0x51
Oct 8 22:05:05 (none) kernel: IDE: read command for sector 4480064 bailed with DMA running
Oct 8 22:05:05 (none) kernel: hda: unexpected_intr: status=0x51 { DriveReady SeekComplete Error }
Oct 8 22:05:05 (none) kernel: hda: unexpected_intr: error=0x40 { UncorrectableError }, secCnt=45, LBAsect=4480275
Oct 8 22:05:05 (none) kernel: Stopping immediate on Ide
Oct 8 22:05:05 (none) kernel: hda: tivo_dma_intr_direct: status=0x51 { DriveReady SeekComplete Error }
Oct 8 22:05:05 (none) kernel: hda: tivo_dma_intr_direct: error=0x40 { UncorrectableError }, secCnt=45, LBAsect=4480275
Oct 8 22:05:06 (none) kernel: hda: tivo_dma_intr_direct: status=0x51 { DriveReady SeekComplete Error }
Oct 8 22:05:06 (none) kernel: hda: tivo_dma_intr_direct: error=0x40 { UncorrectableError }, secCnt=45, LBAsect=4480275
Oct 8 22:05:16 (none) kernel: Stopping immediate on Ide
Oct 8 22:05:16 (none) kernel: IDE: tivo DMA engine aborted
Oct 8 22:05:16 (none) kernel: hdb: irq timeout: status=0x58 { DriveReady SeekComplete DataRequest }
Oct 8 22:05:16 (none) kernel: hdb: irq timeout: error=0x00 { }, secCnt=0, LBAsect=133699136
Oct 8 22:05:16 (none) kernel: IDE: DMA in a strange state
Oct 8 22:05:16 (none) kernel: FPGA callback with DMA not running - delayed interrupt?

The drive is about 1yr old and I'm loathe to replace it 'just to be safe'. Assuming it's simply a bad sector, why hasn't the drive's electronics silently remapped it to one of the good spares? Perhaps the spare sectors are all used up?

Is there a way that I can mark that 'bad' sector as bad at the shell prompt and forget about this? Should I pull the drive and run Spinrite on it (I'd rather not unplug the TiVo if I can help it)?

[blindlemon]

Yes, it's a bad sector and no, the TiVo software doesn't force the drive to remap it as a PC would. You may be able to force a remap using the drive manufacturer's diagnostic software, or I believe there's a linux utility around somewhere that will do the same by writing zeroes to the affected sector.

However, in the longer term you need to replace the drive ASAP, as one failed sector is normally a warning that more are about to follow - and if you leave it too long you risk ending up with a crashed system and a drive you cannot copy. If you do it now you should be able to recover the contents to a new drive with DD or dd_rescue overnight. You can then retire this drive to a life of leisure in your PC or send it back to the manufacturer for a RMA replacement.

[AWT]

Thanks for the response blindlemon - it wasn't what I wanted to hear but I had resigned myself to replacing the HDD!

I'll check if we have a spare PC133/512MB stick at work and if we do I'll be buying one of your cache cards ready to install at the same time as replacing the HDD. The speed of the UI/Now Playing menu is probably my only complaint with my upgraded unit - anything that helps that will be very well received in this household!

An open question now..... I'm sure that I fitted the failing drive less than a year ago - will there be any meaningful date stamps anywhere on the disk that will corroborate that? If I can be sure the drive's in warranty then it's worth me spending a bit of time looking for the purchase receipt from PCW in order that I can get it replaced and have it ready as a replacement for the next time.

[blindlemon]

If you want to invoke the PCW warranty then I suspect you will need their receipt :(

However, if the drive is a Seagate or Samsung then it will be in warranty from the manufacturer and you can do a direct RMA to them.

[AWT]

As far as I can remember this is my drive upgrade history so far:

+ Started with a single 40GB A drive
+ Upgraded to a 120GB A drive
+ Added 120GB B drive
+ Replaced faulty 120GB A drive with a 160GB partitioned at 120GB

I've managed to keep my recordings at each step (so if this looks impossible then I'm remembering it wrong, sorry!).

To summarise, I now have 2x120GB and drive A needs replacing.

Ideally, I now want to upgrade to a single 500GB and add another 500GB once HDD prices fall through the floor. If 500GB + 120GB (B) works best for now then I'm happy to hear about that.

Can I....
Preserve my recordings in any way, such as:
dd'ing the 120GB A up to 500GB?
Venturing over to the 'dark side' and finding a way there to 'persevere'?

Alternatively, is there anything to be gained by a 'fresh' install onto a new 500GB and keeping what's on the 120GB 'B', or is that just too random?

I'm completely open to ideas and suggestions here.

[AWT]

However, if the drive is a Seagate or Samsung then it will be in warranty from the manufacturer and you can do a direct RMA to them.
Thanks, it's a Singsong so I may just RMA it out of spite and use it as a backup on my PC :)

[blindlemon]

+ Replaced faulty 120GB A drive with a 160GB partitioned at 120GBDo you mean you are only using 120gb on this drive? If so it should only have 2 partitions and you could, theoretically expand a dd'd copy to a larger drive.
If 500GB + 120GB (B) works best for now then I'm happy to hear about that.You could possibly do this, but your swapspace would less than the recommended 310mb so if you had a GSOD on the new system there would be a danger it might not complete.
Alternatively, is there anything to be gained by a 'fresh' install onto a new 500GB and keeping what's on the 120GB 'B'Not exactly sure what you mean by this, but as I read it, what you're suggesting is not possible. A fresh install will wipe the new drive, and if you add the old 120gb drive as a "B" drive (not recommended) then you will lose all the data on that too.
I'm completely open to ideas and suggestions here.Copy off all the recordings you want to keep (using methods we cannot discuss here) then make a divorced backup and restore that to your new 500gb drive. That way you can resize the swap to suit your proposed final system and, in the meantime, will be running with a single 500gb drive rather than two drives.