After dealing with the issue for 3 days now, working day and night trying utility pass utility... Ran across the HD Regenerator and a couple other more utilities for fixing bad sector, Boot and MBR... Finally last night I decided to try another utility to fix HD and to make the story short. SpinRite DID the JOB.. Now I'm on my way backing up my entire customer's data... To you all out there if you come across this one... Don't even waste your time trying with anything else that is not SPINRITE v6.0 I take my HAT off!! is the Best Utility I ever tested and prove IT DOES WORK.
My Thanks to you all and go and get SpinRite v.6.0 and have it as one of your friendliest TOOLS.
PS: Hiren's Boot CD v. 7.7 has IT. CASE CLOSE
PC and Network Specialist
my place: http://www.jopcready.com