Use WinMFS.
TivoHD / Series3 Upgrade Instructions
- Remove the outer case and existing drive using a torx screwdriver in the T10 size. If you don't have one of appropriate length, you can purchase the Star Driver T10 Ampro (9014713) from Advance Auto Parts for about $4.
- Download WinMFS here.
- Shut down Windows and attach original TiVo drive. You can open your computer and attach it with a SATA cable, or attach it externally using a SATA->USB adapter like this.
- Boot to Windows XP (SP2) or Vista, run WinMFS, and click 'Select Drive' to select the drive you attached.
- In WinMFS, click the 'Backup' option. Save the file to your hard drive.
- Shut down the computer and attach the new, larger drive. You can disconnect the original Tivo drive.
- Turn your computer back on, run WinMFS, and click the 'Restore' option. Select the file you saved to your hard drive in step #5.
- You're done. Install the new drive in the TivoHD.
Note that won't backup your existing recordings. The "Backup" option in WinMFS just backs up the Tivo software and your configuration, not the recordings.
If you want to backup your recordings too, then you need to choose the MFSCopy option in WinMFS which requires that the original Tivo drive and new drive be connected at the same time -- in which case you may want 2x SATA -> USB adapters.