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· TSF Team, Emeritus
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Bad sectors are a physical fault. Physical faults cannot be repaired with software. Utilities such as killdisk don't actually repair bad sectors but allow the drive to replace them with spares reserved for the purpose. The problem is that there are only a limited number available for this purpose. If killdisk is giving errors then it appears that this limit has been reached. Thus, you need to replace the drive.
 
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