Before you write the drive off as dead, get an app like spinrite to test the drive or see if the drive maker has a disk test application; Spinrite is great but it is not free. If you dont have access to an application to test the drive, use an Ubuntu CD and run the SMART test on the hard disc as well as write zero's to it and retest it.
NOTE: BE VERY CAREFUL WITH THESE COMMANDS AS IT COULD HOSE YOUR BOX IF YOU GIVE IT THE WRONG DRIVE.
Replace sdX with the device name (ex. sda. sdb, sbc, etc). Do this with all the commands listed.
All of the following are commands to be ran from a terminal in a Linux environment like Ubuntu.
If you have the data backed up, then I would suggest writing 0's to the drive and seeing if it throws any errors.
Code:
dd --if=/dev/zero --of=/dev/sdX bs=4096
This will tell you if the drive has issues being written to (badblocks)
Use fdisk to create the partition again, the first line is the command, the rest are answers to its questions.
Code:
fdisk /dev/sdX
n
p
1
(leave at 1)
(leave at default)
w
You should not need to delete any partitions as writing 0's to the drive should have killed it, but if you need to just use (d) and select the partition to delete.
Then test the disk again.
Code:
mkfs.ext3 /dev/sdX1
fsck.ext3 -c -c /dev/sdX1
If the drive has bad sectors this should help you map them out, assuming there are not too many.
Finally, assuming all tests passed, format it to fat32 if you want. I personally like ext3 but I use linux so yeah.
Code:
mkfs.vfat -F 32 /dev/sdX1
FINAL NOTE: If you find you are getting permission issues running these commands, then try to switch to root.