OK I ordered a new WD20EURX (same as old) and it finally arrived. After imaging, ddrescue reported 0 errors, so I was concerned I didn't identify the problem and also swapped power supplies in the limping box. I figure with TiVo reporting I haven't connected in over 30 days that I may have too old an image? So I put the newly imaged drive back into the limper and plugged the network back in. The sw version says 20.7.4d.RC15-746-2-746, is that new enough to be useful, or should I wait until the box updates?If you have another 746 that's up to date I would use the dd or ddrescue command in MFS Tools to duplicate the the drive in the limping unit to your spare, then run a Clear & Delete Everything on the spare to 'marry' the replicated drive to the motherboard. If it works reliably after that I could walk you through the steps I use to get a truly clean image.