|From "secondary master" I assume this is an IDE drive(40 pin connector with a wide ribbon cable).|
How is the drive jumpered? Is it alone on the cable?
Western digital drives tend to have a different jumper scheme than most other manufactures. On all of the WD HDD's I've seen there are two different settings for master, one for when there is another drive on the cable and normally no jumper when the drive is alone on the cable.
Having the jumper in for master when there isn't a slave normally doesn't stop the drive from working, but it does tend to make the drive very, very slow.
I think this could easily be the cause of the failed format, but then again it could also be a faulty drive.
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