Try a Low level format. click the link below for a software to assist you:
http://www.softpedia.com/get/System/Hard-Disk-Utils/HDD-Low-Level-Format-Tool.shtml
You may also try formating the drive from a floppy disk, if needed. But that may require a little experience of DOS.
The formating done at the time of installation is a High level format, which may not be effective in all cases.
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