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Don't trash an iPod with bad blocks on the drive
Authored by: tguk on Aug 18, '12 08:09:27AM

I had been mucking around trying to get my classic 160Gb to work - it would load about 3Gb of stuff and then fall over. I'd tried multiple restores and everything people had suggested and nothing worked. I could'nt get a low level format to work as it fell over when it got to the bad sectors rather than marking them bad (I think it is something to do with the SMART firmware).
Anyway I restored the IPOD on an XP machine, put it in disk mode and then attached it to my Mac and ran disk utility. I couldn't back the image up as it fell over so I just repartioned the disk with the firs 10Gb at free space. I formated the remaining space as exFat and bootable which worked.
I then plugged it back into my windows machine which told me it wasn't formated ... I then formatted it with a command line utility I had found somewhere on the net called fat32format. Now windows showed it as a 137Gb disk. itunes said the ipod needed restoring. I ignored this closed itunes and ejected the ipod. When I plugged it back it it showed up under itunes as a new ipod with only 137Gb of space!
It now works perfectly with the exception that I've lost a little bit of space which doesn't worry me as I only use about 30Gb.
So thanks this post pointed me in the right direction.
The only issue I can see i if I have to restore in the future I suspect the iTunes restore will take it back to a 160GB disk and I'll have the same bad sector problem....

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