Now i remembered something too, maybe the cylinders and heads aren't set to the right values.
Compare them to what says on the HDD and what it says in HDToolbox. If they're different, you still can adjust them in HDToolbox, just select your HDD from HDToolbox' menu and click on Install. There you will see the parameters and other values you can correct if it's needed.
I cannot think of any other stuff atm what could help...