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PDR / Casebook / The Heads Were Worn, and It Clicked Twice

Desk-powered externals · logged · PLY-2025-0903

Two Clicks, and the Heads Had Worn Away.

A family in Tavistock blamed the USB port for the best part of a year. The Toshiba carried ten years of their two children's lives, and its one visible symptom was that it kept slowing down a bit more every month. Windows then threw a fatal hardware error, which took the port out of the argument. Tried on a neighbour's PC, it never appeared on his laptop either. By that stage it would start up, click twice, and turn itself off.

The customer checked and agreed No names published

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Why it happens.

Calibration and adaptive tables live in a reserved band on the platters. Nothing can present itself to a computer before those tables have been read, and heads this thin were unable to lift them. What happens next is by design rather than by accident. Two attempts are permitted by the firmware, with a recalibration between, and then it stops rather than work from figures it cannot trust. The clicks are those two attempts. The slow year in front of them was the same wear accumulating without a sound, and the Windows message merely said aloud what the disk had been indicating all along.

The kit this job called for.

How the job runs →
The kitWhat it did hereWhy we keep it
DeepSpar Disk Imager 4Measured each head on the replacement stack and fixed the order the surfaces were read inScores every head before it starts, works one surface at a time, and holds resets, timeouts and power in check
PC-3000 Data ExtractorRan the passes, meeting every stall with a controlled reset or a drop in powerThe PC-3000 runs the copy through the drive's own firmware
R-Studio TechnicianPut the folder structure back together from the completed imageReads nearly every file system, and rebuilds RAID sets from images

How it ran.

01

The noise counted as evidence, not as a nuisance

Two clicks every time, never three, then a shutdown. Ordinary use does not produce that; the power-on read does, which puts the reserved tracks at the head of the list. Magnification agreed. No chipping, no impact marks, just even wear right across the sliders after an enormous number of hours in the air.

02

Heads first, before anything else

A stack from the same production run was fitted, after which the disk completed its start-up read, held power and reported its own identity. Mapping came immediately instead of later: wear this gradual seldom spreads evenly, and only the map shows which ground still holds readable data and which does not.

03

Copy it straight away, best heads leading

Nothing worn this badly will hold still for a second go, so the copy was started the moment the repair was finished, the drive never leaving the bench. Full rate on the sound heads to begin with. Doubtful bands were set aside for slow passes at the end, after everything else had been taken. With the reserved area readable again, almost all of it came off without argument.

How it ended up.

The image finished complete. Everything was pulled out of that copy rather than off the disk, and the folders were checked a year at a time before the case closed. The Toshiba was scrapped: a drive that has ground away its own heads has nothing left in it for anybody.

In short: A drive losing speed month after month is trying to tell you something. When it clicks twice at switch-on, the telling is over.

Seeing the same thing?

Leave it switched off and post it in. Nothing happens until the diagnosis, which lists what can still be read and what cannot.

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