if you can't partition and format it with windows disk or drive management call it in for exchange. No, I've never had to move it to sata to format it.
i had a problem with a 1tb seagate drive. i sent it in for a replacement. i opted for a rosewill usb external housing. win xp found it and installed it saying new hardware is ready to use. it does not appear under my computer anywhere. the device manager shows the drive and ids it exactly. i can remove it and reinstall it and each time it says ready to use. should i connect it to the pc via sata cable and format it and then put it the usb housing? any thoughts on this? pc is hp media center with AMD dual core 1.6 processor. in the device manager i can ask it to populate and it shows near 1tb capacity with all of it usable. it just wont assign a drive letter. i went to command promt and diskpart then list volume [its not there].