Well it started off with some playback problems and then the Tivo started to hang requiring a powering on/off to recover for a few weeks, finally GSOD and a constant reboot.

Pretty sure my swap file big enough (can't check now) and on pulling out the disks I have found that my second drive has failed, tried various tools/utils etc but they all fail and give me a warning that its on the way out so its into the bin.

Moving on, as the Tivo is out of service I have ordered another 300gb disk (same as the primary) and I believe I should be able to put both into a pc, do the mfsadd to marry the drives as I do normally and away I go.

I'm assuming its not an issue to do the mfsadd a second time to the primary (as I added the original failed second drive) and it will regig its allocations etc?

I should also be ok with the OS and hopefully will keep the shows, season passes etc that were on the primary drive?