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Cannot properly set Partition Size

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Old HD = 640G and consists of 100Mb SYSTEM, C: 590G, D: (factory restore) 11G (it is working but fails SMART test - thus my desire to replace it)

New HD = 1T, both sata, only one cable/power. backup done and validated.
on boot it doesn't always show the backup - I have to do a REFRESH (manual says nothing about this) and this works (I mention this because on my second computer, when trying to do a validate, it hangs when I do a refresh saying "ANALYZING PARTITION for 6 hours before I turned power off).

So I select the C:, D:, and SYSTEM to recover. The details show the following: 1 MB, SYSTEM (100MB), C:, then D: on the current HD (Windows 7) in that order left to right.

when I get to partition size it won't allow my to set 100MB as the partition size!!!!! Your manual is woefully inadequate in this area. I THINK I'm suppose to do this... but not sure. Anyway it shows the new location as 931GB with 635 free (have no idea why it is doing this - must have something to do with the fact that the current one is 635G)

The partition size always adds up to 931G. I can't set the size to MB at all - the minimum it will allow is 295.5GB. I've no clue where to go from here. No "sliding" or entering below a size of 295.5G.

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Gary,
If the old disk is MBR (not GPT), you can use the instructions located in link #3 below and select item 1 which is restoring to a larger/smaller disk. This is a restore procedure restoring a previous full disk backup and the backup must include all partitons including all hidden partitions.

You need to use the TI Recovery CD and also do the "add new disk" routine.
When completed, shutdown and disconnect the source disk so the new boot is only with the new 1 TB disk attached.

If you are having trouble with any of the disks being recognnized, try other connectors or cables.
if your computer is a desktop, use the connections in rear for usb connectors. Do not use a usb hub, etc. If using usb3 and have troubles, try using usb2.