Hard Drive problems / unable to Zero out Data etc.

Hallo.
Here is the problem: I have several WD Raptor Hard drives 74 GB working without problems. One of them is my system drive , others are used as Sample libraries HD or HD for recorded audio (I have Firmtek SATA card so I can use more SATA disks...). This summer I bougt new WD Raptor ADFD 150 GB drive to expand my storage for Audio Data... But I encountered a few problems like when I tried to copy a folder from this HD to another and this folder was quite big (15 GB or more) , it never get copied completly and the copiyng freezed in the middle or alike. So I had to move subfolders of this "big" folder manually... Also when I backupped Data from this drive to another with Apple Backup 3 it SOMETIMES did not backup and freezed. This happened in case of creating new backup file to new location, not when backupped to location with already existing backup file.
I tested the drive with the OSX Disk Utility (Verify Disk) and it said it was OK. Than I tested it with Tech Tool Pro 4 (Surface Scan) and it found a few ( two, sometimes three) bad sectors. Sometimes TecToolPro also freezed and I had to Force Quit it or shut down my Mac by pressing the Power button. So I moved the data away from this disk and tried to Erase it (Zero Out Data) with Disk Utility. Disk Utility started and reported that it will take 27 minutes. But after a few minutes it freezed and did not finish eerasingúzeroing the disk (I let it for whole night...). And Disk utility freezed so I had to Force Quit it. I tried it many times without success. Disk utility only could Erase it or create new partition but never Zero Out Data. Than I tried to Zero Out this disk in SoftRaid utility (even this disk was not in SoftRAID or any RAID setup) and it worked. But after I Scanned it's surface in Tech Tool Pro again, it found the bad sectors again...
So I took the disk to my computer dealer and he gave me new one - the same WD Raptor ADFD 150 model. I installed it (in lower bay inside my G5) , initialized in Disk Utility and than I did run the Surface Scan test in Tech Tool Pro. I could see the number of block that were tested increase for a while but than it stopped for a few minutes (10 or more ) and after a while it reported that it found 39 bad sectors! Wow! Fresh new Hard Drive! So again I tried the whole process: to Zero Out this new disk in Disk Utility and Disk Utility freezed. But SoftRaid utility Zeroed this disk successfully - but than after this procedure TechToolPro reported that 1 bad sector was found... I need to say that the Surface Scan test in Tech Tool Pro never got finished (only once when I let it work for about 6 hours) as it reported about bad block(s) after a few minutes or it freezed after a few minutes...
SO I took this new disk and installed it to a PC I have and I tested it with Western Digital Datalifeguard diagnostic utility (from Floppy disk). All tests were fine. It also wrote Zeroes to whole disk without problems. Fine. I reinstalled the disk back to my Mac and even before I initialized it in Disk Utility I tried to Scan it's Surface in Tech tool Pro. After a fef minutes it probably freezed , as it is scanning Block 19744512 for ever now - and it found three bad sectors already...
So what do you think about my situation? Shall I trust the Western Digital diagnostic utility (but on a PC) or should I visit my dealer again?
PS-I have Tech Tool Pro 4.1.2
Message was edited by: Diamond Dog

Something to try:
Open Disk Utility (Applications > Disk Utility)
Select your external HD on the left side of the Disk Utility window
Check the partition map scheme, near the bottom of the Disk Utility window
If it is not GUID (assuming you have an Intel iMac), consider repartitioning your HD to GUID. The Windows partition scheme on many external HDs. FAT 32, often has problems accepting large data transfers from Mac-partitioned hard drives.

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