I recently disassembled my old Archos Jukebox 6000 in order to install a 120GB replacement hard drive in it, along the same lines as mentioned
here. Using Partition Magic 8.0, I formatted it for FAT32 as a primary partition and then reassembled the whole thing. After installing the drivers and getting everything sorted out, Windows recognizes the partition. However, when I power the device on, it reverts back to reading "Jukebox 6GB Ver : 4.09" and hangs. I've tried to alleviate this issue several different ways, including downgrading to Rockbox 3.0.1 and then to 2.5, reformatting using different programs, formatting it down to just 6 gigs as the original had, but none of these made the hang screen go away. Finally, I formatted and turned it on with nothing on the drive. Interestingly, same results. It appears then that the hardware isn't reading the drive at all and is instead reading the firmware from internal ROM or something like that.
Is there any way for me to fix this? I'd rather not have to disassemble the Jukebox again as I have to use a swiss army knife to remove the smaller screws and I already stripped the head of one of them fairly badly. I will if it's impossible to fix otherwise, however. I know it's not that the drive doesn't work because as I said, Windows reads it perfectly fine and I made sure that the drive I ordered was the right size and connection type to act as a replacement for it. Any help would be greatly appreciated.