I/O error on internal hard drive access

Hello,
It seems that this problem keeps coming back for me.
Today, I've been trying to install the 10.4.3 update, but it keeps failing. I get this error on my system log:
Oct 31 21:41:22 My-Computer kernel[0]: disk0s3: I/O error.
Before attempting the upgrade I did a backup. The backup was unusually slow, probably related to the same I/O issue. I am getting the I/O errors with other operations that access the hard drive.
As background information I had my logic board and power supply replaced four months ago for similar hard drive access issues (that time the whole system went dead after clicking noises coming from inside the iMac). A few weeks ago the clicking and beach ball hangs reappeared, but went away just when I was going to take the iMac to the Apple store.
Rebooted with the external drive and disk verification has given me some key error. Attempts to repair have failed. S.M.A.R.T. status is Verified.

That's what I'm planning to do tonight, plus DiskWarrior. By the way, DiskWarrior last night gave me a warning saying that the speed was limited due to hardware problems, if my memory serves me well. For now it seems it is an on and off kind of problem. What bothers me is that this time the filesystem got damaged. I'm thinking of taking the iMac to the Apple store this weekend.

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    -1 Stick "ValueRAM - KVR 133 x 64 C3/512" in PC 133 DIMM slot **
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    -1 Pioneer "Superdrive" DVD-R/W/CD-R/W on Internal ATA 0 ID=0
    -NVIDIA GeForce2 MX with 32MB SDRAM in AGP Slot, feeding a 17" Apple Studio Display.
    -PCI Display Card "formacGA7" - not attached to any external device, not sure what its intended purpose is.**
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    -1 Canon GL1 MiniDV camera, attached either to the other FireWire port, or to the last drive in the chain, depending on my urgency/laziness factor. BTW, FCP 3 has worked flawlessly controlling this Cam for logging and Batch Capturing.
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    -Software Install, OS 10.0.4, CD vers 1
    -Software Restore, OS 9.2 & 10.0.4 CDs vers 1, Discs 1-4 of 4.
    -OEM Apple Hardware Test; Power Mac G4, SW vers 1.2.1
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    -After Effects 5.0
    -QuickTime Player 6.0.2
    -Toast Audio Extractor 1.1
    -Toast Titanium 5.0.2
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    -Microsoft Word & Excel
    # of other Applications on System Hard Drive I either don't use or may be integral to the system: 260
    # of Control Panels:
    -Enabled: 34
    -Disabled: 0
    # of Extensions:
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    -Disabled: 0
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    -Bought a copy of MacDrive so I can see what's on my External Drives on the XP machine.
    -Printed out System Profile before I installed upgrades.
    -Thoroughly searched this discussion board for and gathered as much info as I could before upgrading.
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    -Never ran any sort of Disk Maintenance, even after one of the Externals crashed (DiskWarrior saved my butt on that).
    -Ignored some of the advice on this discussion board.
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    RECENT UPGRADES:
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    Turned off system, disconnected all External FireWire Devices, disconnected Monitor, opened case, touched various metal parts of case and power supply to discharge any Static, unplugged power cable.
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    -Installed 1 Maxtor "DiamondMax" Ultra ATA/133 100GB Hard Drive (8 MB buffer) as "Slave" (no jumper) in top of U-Carrier above System Hard Drive; attached to middle of original Apple ribbon cable, attached available power plug.
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    A few hours later, I plugged the MiniDV and an External Drive into the FW ports and powered up the System. It was behaving extremely sluggishly. I would click on something, the pointer would turn into a wristwatch (sometimes with the minute-hand moving, sometimes not) and like an actual minute later, what I'd clicked on would open. All three drives were on the desktop, still had their files, and "About this Mac" still showed 1.5GB total Memory. So I powered down, disconnected the FW devices, waited a bit, and powered back up. Same sluggish response. I tried to open my FCP project file, and instead got a Window that said something to the effect of "The Application associated with this document could not be found". I think I tried to open FCP from the Applications folder on the System Drive and got the same message (I'd only had 3 hours sleep, no coffee, my client had died, and his family was coming for whatever I had in a few hours).
    LAME ATTEMPTS AT PROBLEM SOLVING THAT HAVE MADE THINGS WORSE
    Panic had set in, which never solves anything, so I don't remember what order I performed which tasks, between searching for clues in this forum, and convincing myself that that would be faster than trying to compose a question, waiting for a response, etc.
    The first two things I did, and I can't remember which I did first (both from Keyboard Commands during Restart):
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    PRAM Reset
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    I tried restarting without extensions.
    I would get errors that said something like "Not Enough Memory to Open Finder".
    I tried booting from Disc 1 of the Software Restore Disk, which only wanted to destroy my data.
    I tried booting from the OS 10 disk, with the same result.
    I was finally able to boot from the OS 9.2 Software Install Disk, and actually saw both internal drives on the desktop, and the 1.5GB RAM in About this Mac. I tried to allocate more memory to Finder, but was informed that "Cannot Perform Requested Operation. This operation requires versions above 8.0".
    I think at this point I decided that I must have too many extensions, and started disabling ones I thought irrelevent to my cause (mostly anything that said "AOL", "Airport", "Ethernet", "Printer", "Modem", "Speakable", and a couple things called "Open TPT".
    It gets worse. Then I decided to turn off some "unnecessary" things via the control panels, but somehow managed to disable the control panels themselves: AppleTalk, DialAssist, File Sharing, Modem, Mouse (as I saw that Microsoft Mouse was among the others), Remote Access, Speech, USB Printer Sharing, and possibly TCP/IP.
    That certainly didn't help anything (though upon restarting from the OS 9.2 Disc I was able to see the extensions and control panels in their respective "Disabled" folders in the System Folder). But I still wasn't able to get more Memory to Finder.
    So, I decided a few more PRAM resets might help, which succeeded in making both Internal Hard Drives disappear. I tried booting up from the DiskWarrior disc, but even the Mighty DiskWarrior couldn't find the drives. I performed the longer, in depth version of the Apple Hardware Tools tests, which reported that everything's fine (including the new RAM), but made no mention of the Hard Drives at all. The deadline having long passed, I shut the system down. I read through more posts and tech articles, etc.
    I searched my External drives with MacDrive on my XP, and found the drive that has the copy of my System Folder (which shows all extensions and control panels as enabled); not sure if the Quicksilver will boot from that, I don't know what the Keyboard command for booting from a FireWire drive is (if there is one) and the drive itself only has 900MB of free space.
    I can't find any reference to Internal ATA drives anywhere in the MacDrive documentation; if it was possible I'd put them into the XP, get the files off the Mac drives, reformat them and install OS9 from the Discs.
    This is where I am now:
    The Quick Silver is still powered down. I removed the Microsft mouse and replaced it with the OEM Apple mouse. I opened the case, and removed the PRAM/Backup battery (manufacture date: July 2001). Couldn't find my voltmeter, so took the bat to Radio Shack and bought a new one. Had the Radio Shack guy test the old one: it showed 3.69 volts still. Have not installed the new battery yet. The case is still open, waiting for any advice any of you might have to offer.
    Thank you all so much for your patience in perusing and pursuing this.
    Sincerely,
    Patterson
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    The jumpers are correct for both Maxtor Drives.
    Rodney, you are correct in that the initial problem (slow rendering/"out of Memory" crashes) was caused by my not realizing I'd stupidly captured several GBs of media to my system drive, and not checking which drives those files were on (as I'd assumed I'd put them on one of my external media drives) once that problem presented itself.
    Before I'd determined what I'd done, I bought the extra RAM. After I'd found the media files on the System Drive, and saw that my dedicated media drives were too full to easily move them, I decided to buy an additional Internal drive so that I could:
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    -Juggle all my media into a more organized fashion for archiving (as most of my projects are on-going long-term affairs)
    -Wipe it, Partition it, and clone my System Drive onto it, as a spare bootable drive in case my OEM System Drive failed.
    Copying the Media files onto the New Drive and moving the System Drive's Media files into the Trash worked great: huge improvement in Rendering, etc.
    Before shutting down for the night I Emptied the Trash, and was pleased with the amount of space I'd freed up on the System Drive.
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    It was trying for a few minutes (the gray screen went black at one point, and then returned to gray) before presenting me with the flashing question mark.
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