Did Hitachi buy IBM or something?
I had one 40GB Deathstar die a couple years ago, but the other one is still going strong with one death under its belt. It died and couldn't even be recognized by the BIOS. I froze it, pulled all the data off of it, and it still kept going. It's worked ever since.
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Check your motherboard's IDE firmware. It may have to be patched to support larger capacity drives [unlikely]. Also see if you can format it with a different OS than Win9x.