40GB Upgrade for iPod 2.Gen (20GB)?

I've tried to upgrade my second generation iPod (20GB, Windows) with a 40GB HD. I've got the iPod to work with the 40GB HD, but it refuses to work with my PC thru Firewire. The (Windows-)PC didn't recogize the iPod with the 40GB HD at all, so I couldn't sync new MP3s. This is still an open point. If anybody can help - please let me know.
If anybody wants to try this with the Apple-version (HTFS) and has more success with the sync to his Apple-PC, let me know too.

What you need:

Toshiba 1,8" 40GB-HD MK4004GAH, (ex. from F&M Online Shop Germany)
This HD has the same physical dimensions and the same connector like the built-in 20GB-HD (Toshiba 1,8" MK2003GAH)
external USB-Case for Toshiba-1,8" HD, ex. c-enter from Pearl (PE3457) (Germany)
Linux-PC with 40MB free HD-space
Windows-PC with 20GB free HD-space (if your iPod is full with MP3's, otherwise only the occupied space on your iPod is needed)

What to do:

Install the newest Firmware (1.4) with the Apple Install Tool to your iPod
Copy the complete iPod-filesystem to your Windows-PC. Don't forget to copy the hidden Folders 'iPod_Control' with the subfolders
Open your iPod carefully with a knife. Start at the bottom left or right corner to the side.
Disconnect the battery
Disconnect the HD (Toshiba 1,8" 20GB MK2003GAH)
Connect the 20GB-HD with the USB-Case and connect it to the Linux-PC.
run the command 'fdisk /dev/sda' (or however your USB-HD was named, you can check with 'dmesg') and choose 'p' for viewing the partition data. It should look like:
```
Partition Boot Start End  Blocks   Id FS
sda1      *    1     5    40131    0  Empty
sda2      *    6     2431 19486845 b  FAT32 WIN95
```
Now you can exit the fdisk with 'q'. Nothing was changed!
Make an image of the first partition (sda1;39MB) to your PC with the command 'dd':
dd if=/dev/sda1 of=/temp/ipod-first-partition
Disconnect the USB-HD and reboot the Linux-PC
Connect the new 40GB-HD with the USB-Case and connect it to the Linux-PC.
Run 'fdisk /dev/sda' and generate the partition table on the new HD.
Delete any existing partition (command: d)
Create a new primary partition (n p 1 1 5)
Create a second primary partition (n p 2 6 'default')
Set ID to 'Empty' for the first one (t 1 0)
Set ID to 'Win95 FAT32' for the second one (t 2 b)
Make both active ('set bootflag') (a 1; a 2)
It should then look like this (p):
```
Partition Boot Start End  Blocks   Id FS
sda1      *    1     5    40131    0  Empty
sda2      *    6     4863 39021885 b  FAT32 WIN95
```
Write changes (w)
Format the second partition with FAT32 on your Linux-PC (Windows XP can only format up to 32GB with FAT32!) For this run:
mkdosfs -F32 /dev/sda2
Write the previous saved image of the first partition to the new HD:
dd if=/temp/ipod-first-partition of=/dev/sda1
Connect the USB-HD (40GB) to your Windows-PC
Copy the previous saved iPod-filesystem to the FAT32-partition of the new HD.
Disconnect the 40GB-HD from the USB-case and connect it to your iPod. Connect the iPod-batterry too.

Now the iPod should run as before but with the 40GB-HD. In the 'About'-Section of your iPod-menu, there should be 37GB capacity shown.

But the iPod will not be recognized from your Windows-PC anymore. Has anyone any help for that?

Axel Findling, 2004-11-14
last changes 2005-01-18