I recently had to do this, and several knowledgeable folks on this forum gave me good advice on how to do it.
I did up the following guide and I am posting it here, just in case it may be of assistance to others who need to do this. Addendum: It is a good idea to have all your data backed up before proceeding.
Adding and Preparing a New Hard Drive (Window 7 and Vista)
1. With power off, physically install the new drive and hook up power and SATA cables.
2. Boot up and the system should install the driver for the new drive.
3. Restart and open the bios. The new drive should be detected as a SATA drive. Save & exit.
4. Once windows has started up again, click Start, and right click on Computer.
5. Click on Manage, then click on Disk Management in the left side tree. A window will open up and should show the original drive as disk 0, as well as the new empty drive as disk 1. It should also show any other drives (such as cd-rom’s) all sequentially numbered.
6. Right click in the open space of the new drive, then click on New Basic Volume.
7. A utility will open and guide you through assigning a drive letter (the next available), then a file system (default is NTFS), then volume label (default is New Volume), and an option for a quick format (full format of a new drive is recommended, later), then finish. Click Finish and wait until complete. This won’t take very long.
8. Back in Disk Management the new drive should now show the assigned letter, the drive label, plus “healthy primary partition.” If you re-open Computer the new drive should show up, along with the original. It should be completely empty. We are making progress!
9. If the drive is brand new, it should be fully formatted before use. To do this, in Disk Management right click on the open drive space. In the window that opens click on Format. The next window allows a choice of a volume label. Make any desired changes.
10. Leave File System and Allocation Unit Size at their defaults. The next check box called “Perform a quick format” needs to be un-checked so as to force a full format. Then click on OK.
11. A window will open warning that any data on the drive will be erased. Just click on OK since we know this is a new drive.
12. Formatting will now begin as shown in the Disk Management window as a percent complete number. This is a slow process, so go grab a coffee. A 500 GB drive can take upwards of an hour, and a 1TB drive upwards of 2 hours. You can minimize the window and do other work as needed, since it uses very little processor bandwidth.
13. Once formatting is finished it will show in Disk Management as a “healthy primary partition”, (which is no different than before.) It is now fully ready for use.
14. If the new drive is to replace the original, you will need to clone the original drive to it, including the system boot sector. To do this go to the drive manufacturer’s site, and download the applicable drive copying utility. (In the case of Western Digital, the utility is actually Acronis True Image.)
15. Install the software and open it. Select the option for cloning or making a complete copy of the existing drive, including operating system. A window will open that allows you to select the source and the destination drives. Do this carefully! Once selected, click on finish. The system will ask to restart, then the cloning will begin. This may take anywhere from a couple of minutes to an hour or more depending on how much data is on the original C: drive.
16. Once the copy is complete, shut down the system, unplug and remove the original drive.
17. Restart and enter the bios again. Go to the boot order and select as desired. Save & exit.
18. Windows should now start up from the new drive. All folders and files should be intact.
19. If you open Computer, you should now find that Windows has re-lettered the new drive as drive C: automatically, since C: is the Windows default boot drive.
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