TiVo Series3 / WinMFS fails to expand as expected

I have a TiVo Series3 (OLED TCD648250B). In 2010 I updated the drive to a 1.5T WD EARS HD and expanded it up to the 1.26T capacity via WinMFS. I turned off intelipark via WDidle3 /d. This worked fine for 2.5 years. The S3 has recently begun to reboot and so I decided to just re-image a new drive. I took backups of my original 250G HD in 2010.

So I restore the image to another WD 1.5T with intelipark turned off, I answer yes to expand and then supersize it. Put it back into the Tivo and it reports 36 hrs of HD capacity, when I expect to see 157 Hrs.

I am following these steps here, exactly.

• In WinMFS, select File -> Select Drive and select the new replacement SATA drive
• In WinMFS, select File -> Restore and select the backup file you saved earlier. Click Start. This will restore the TiVo software to the new drive.

Note: Do not change the swap size. Leave it at the default of 128.
• When the restore is complete, WinMFS will ask you if you want to expand the drive to use the new space. Click Yes.

If you do not see this dialog box, then select Tools-> Mfsadd.
• Select Tools-> MfsSuperSize -> On.

I’ve done this half a dozen times now with different drives (all WD 1.5T) and I even downloaded a new version of winMFS ( beta 9.3f) and every time it does not show the expanded capacity to 157Hrs.

I am using an eSata drive dock and winMFs sees the drive just fine and does the image OK.

I tried to do the kickstart 54 and it just would not take, not sure what I was doing wrong there.

I downloaded a virgin image from a member here via dropbox for my S3 model, restored from that one too and it also reported 36 hrs.

What in the world am I doing wrong/missing? I don’t recall any of these issues when I did my upgrade in 2010.

I don't care about the content on the old 1.5T HD. I can get the S3 back up and running, but kinda wanted to get full use of the new 1.5T HD to get me back where I was before.

thanks for your help.