Internal hard drive replacement issue...(a bit wordy)

I am the second user of this white core duo MacBook - the boss's hand-me-down.
The original hard drive was almost full when I received the unit, so after using it for a while I decided to replace the internal drive. I have an external WD 320GB "My Passport" formatted for Mac use that works just fine - it keeps the Time Machine backups on one partition and a Carbon Copy Cloner image of the original internal drive on another.
I recently bought a WD 250GB Scorpio Blue (WD2500BPVT-00ZEST0), stuck it in the computer, formatted it (Mac OS Extended (Journaled), GUID) as a single partition and put the CCC image of the original drive on it. All was good. New drive booted and functioned as expected. Four days later it failed (question mark appearing on restart attempts). The disk utility applications in four different OS's failed to recognize the disk. Short story is WD sent me a replacement, but 320GB rather than the 250 - a WD3200BPVT-00ZEST0.
I eventually got the new drive partitioned and formatted and installed Snow Leopard from my update disk. All this transpired with the drive docked in an external USB dock.
During the OS install I took the opportunity to set it up in my name rather than my boss's name. (was this a mistake and the source of my problem, I wonder?)
I can boot from this newly built drive when it is docked, BUT NOT when it's installed internally in the laptop. It is recognized as an available start drive during restart, and I get the "apple", but the spinning wheel keeps on spinning without actually booting (or at least I get tired of waiting and the fan keeps spooling up - I eventually just turn the power off).
Is this drive, at 320Gb, too big for this laptop to use internally? (but the 250GB one worked)
Did I make a mistake in creating a different default ID (me rather than the boss) while installing the OS? Is the laptop "remembering" the user setup from the original small drive somehow and refusing to work with the new drive's new user?
This is my first "Mac" experience and I really like the way the OS treats me and the "look and feel" of the GUI, but this has been somewhat frustrating. (I WILL stick with it though, I plan on buying a new MBP next summer.)
Am I forever destined to live with the tiny original drive and be relegated to carrying around Passport drive to get most of my data files?
I now have three drives I can boot from, but I'd really like to have the big new one actually usable from inside the laptop rather than sitting in a dock (with all it's cables).
Thanks for reading this far.
Dave
Message was edited by: Dave Swinnard

Dave Swinnard wrote:
Booted from the SL update disk and ran disk utility to attempt to erase the existing data and repartition - no go. Attempts to erase, change partition size, repartition, verify, or repair all met with an error about being unable to unmount the drive.
OK, so push ahead...
He's dead, Jim.
The hard drive works outside of the laptop.
Your USB enclosure probably runs slower or something.
Has there been some (unknown to me) change in the specifications of 2.5" SATA hard drives since the original one was spec'd for this laptop that renders the newer ones unusable?
I prefer to have other people keep up with this stuff instead of me. I buy pretty much all of my equipment from OWC. If they sell it, it will work with your Mac. Even if you don't buy from OWC (but you should), if you buy the same model numbers that they sell, you should be fine. OWC doesn't sell this drive. For me, that would be a red flag.
(WD claims their "advanced formatting" is OS X compatible without the realignment required by certain versions of Windows, but is it possible this is a hardware related issue with the MacBook?)
OWC does sell the "regular formatting" version of this drive (WDGWD3200BEVT). Perhaps it only works in newer machines. The WD support page also mentioned that cloning can screw up the drive. I never recommend cloning except in some very specific circumstances. I do that not because I know something, but because I don't. I'm not entirely sure what those clone tools are doing underneath and if they've been tested on these new drives.
Maybe put it back into the enclosure and partition it again into a single volume. Make sure to use the GUID option. Don't do anything else with it. Put it back into the Mac and try again. If it fails again, get a different drive.

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    Anyway - ran disk utility - but no errors this time. Which is good.

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    http://www.newegg.com/Product/Product.aspx?Item=N82E16827118021
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    For a new hard drive try Newegg.com http://www.newegg.com/Store/SubCategory.aspx?SubCategory=380&name=Laptop-Hard-Dr ives&Order=PRICE
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