eggheads low level format should work.

If you don't want to do that then download this WipeOut it works very very well and does what FDISK can't. Read the *read a me* & remember WipeOut is super strong all partitions will be gone !!! Then format with XP but not the quick format, use the slow format because it will check the HD for bad sectors & fix them if it can....if it can't fix then it will flag the bad sector and re-map the HD so bad sector won't come into play