lagb wrote:
It seems to me that if the BIOS is unable to reliably communicate with the drive, the drive pcb controller board ROM must be defective.
IMHO that's the wrong guess - the ROM is one of the parts that is likely to be OK, especially given that the behaviour varies intermittently.
Have a read of these articles for a bit more overview of what drives need to do internally, before they are recognised by the BIOS:
newbie-info-from-and-for-newbies-about-firmware-etc-t6562.htmldiy-what-the-big-deal-t12671.htmllagb wrote:
I am tempted to replace it if I can find a donor which is the same model and close in manufacture date, serial number, etc.
Swapping the PCB requires more work than just getting a donor, can require specialist extra equipment (which you won't have) if the ROM is not separate, and in this case is anyway
likely to be a waste of your time and money. Of course this is just a remote guess, based on very limited info - diagnosis may change when someone with suitable experience has the drive on their bench...
lagb wrote:
Can anyone tell me what it means that it is intermittently seen in the BIOS and never bootable? What is the most likely problem?
Sounds like an internal drive problem to me - likely heads. That is not a sensible, low-risk DIY replacement option for you.
IMHO your next choice is whether to go ahead with some attempts at DIY recovery,
without opening the drive, but with the risk that
you may cause more deterioration in that drive during your attempts, and therefore make any later recovery attempts by a pro more difficult / expensive or even impossible. Choices depend on your skills, available time, budget, value of the data to you, your decision about risks you want to take etc.