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Thanks Lemon for your input...I figured as much too, and did a lot of program uninstalls and reinstall as well...just couldn't seem to pinpoint it. And more trouble started creeping into the install. I needed to deliver this unit, and move on so I had to wipe drive. The new install this time...

So far that hasn't been the answer either. I like Spybot S&D, Spyware Blaster, and AD-Aware..thinking it may be an OS corruption, and gonna try a ERD repair.

This is a new build and all drivers, updates, service packs etc, have been done. Would be OK except that when you shutdown from start it says it is saving settings, then is shutting down, but it goes to the sky blue screen and hangs..does the same with restart. I've left it go a couple hours and...

I have tried to do a thorough surface scan on D: drive cable as a secondary master from the dos prompt. It always says can't read from last cluster of this drive. When scan hits about 85% of D it starts to repair bad clusters, sector after sector, except after numerous tries it never finishes...

JON...will try that...but as I recall the surface scan gets to a bad sector near the end of the first partition(C:) and wants to fix every cluster in there...after 150 or so manual clicks I gave up....some 3500 to do. Is there any way to have the whole area marked off as bad? Also I presume you...

OK ...also trying for help at another forum, and thought I had that fact here too....the ATA card seems fine, as this 30 gig spare on Promise comes up in safe mode. But when I try to boot the old drive alone on the primary mobo ide as master, it goes to the scan disk loop, 'can't read from last...

Guys.. your not trying....the problem drive is a secondary master on its own 80 wire cable thru a Promise ATA card. The new drive is primary master on its own 80 wire cable on the mobo. Cables are good and all jumpers and settings are correct, as this set was run for 9 months this way...the only...

Yes, scan disk will complete with perhaps a drive size correction, but on the surface scan windows tries to repair a whole sector of clusters having no data, with 'out of memory error' coming up after about 100 clicks to repair bad clusters. This drive has passed the extensive recertification...

TT4U... Thanks,..yes all controllers are set properly and bios settings are on auto. This was setup before as a two drive, primary and secondary masters, but after an RMA, the new drive is now the boot drive. I swapped cables so the spare is secondary master, which was my primary harddrive...

Installed and cloned a copy of my C drive to a new HDD. The new drive I have booting and working fine, but now when I try to hook up my old one as a secondary master, windows stops loading at the background color and the infamous error 'Explorer has performed and illegal operation...' and the...