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blindlemon said:
Unfortunately, as you've guessed, your problem could be just a single dodgy sector - and while this would not be a problem in a PC, the TiVo has no code to force the drive to reallocate bad sectors, so it's bad news in a TiVo.
Modern disk controller will mark a sector as bad and mark it pending for replacement. It will automatically be mapped out the next time the sector is written to. Just delete the recording and the bad sector should get remapped the next time the sector is rewritten. If you get too many of these, it means your drive has probably seen better days and should be replaced.
 
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