Steve615: Any authorized solution to your failing hard drive will involve the loss of all of your recordings. Some solutions which involve violation of your customer agreement also would cause the loss of your recordings.
1. The simplest authorized way to take care of a failing HDD in a HR54, is to sign up for DIRECTV's protection plan and when it is in effect, and you have definite signs of the failing hard drive, call customer service and have them send you a new HR54, if you canget one. They may try to upgrade you to a HS17 Genie server, with an additional client. That would start a new 2 year commitment AFAIK.
2. Does your HR54 have an ESATA port? I hear that some later models don't have one and can't add an external drive. If you have the ESATA port, you should be able to buy an External ESATa drive, or an External ESATA case or docking station and a high quality 4TB drive like the WD Purple I mentioned. I believe the HR54 is limited to a 4 TB drive size, don't try anything larger. Adding the external drive disables the internal one.
3. I use a couple of different Esata docks. I can't find them online anymore. The only one i see on Amazon is StarTech SDOCK2U33EB. I can't comment on quality of the Esata enclosures, Esata external Drives, or Esata Docks on the market today. THe Esata interface is largely being replaced by the high speed USB ports.
3. Replacing the Internal drive is technically quite simple, but violates your customer agreement. Here is a Youtube video showing how it is done. He uses a bent large paper clip to release the latches. I just used a flat bladed screwdriver on my owned HR54. You do need a torx securiy bit (I got some at Harbor Freight),
We have lost a lot of information on this subject from online forums. Anything that we had at Iamanedgecutter has been lost. If there is anything at the other DBS forum, I couldn't find it.
It is possible, if you remove the original drive to copy it and expand the available space to use the whole new hard drive with a PC booted into Linux and using the GPARTED program. I did it, but I had some instructions.
The partitions on the Genie HDDs are not standard Linux file systems. Copying means you have to connect the old and new hard drives to a computer at the same time.