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Try turning off the drive's write cache (dkctl wdN setcache r) and
then overwriting the drive a few times.

Assuming your problem is a matter of bad sectors that need to be
remapped, and not something more severe, this may well help.  I've
observed enough drives remap sectors this way, that were not remapped
otherwise, that I now assume drives don't remap properly without write
cache.

Assuming this does help, please post the drive's identify output, so I
can add it to my list.

--
Dan.

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