From Google
1. Took out the PS3 HDD (clicked open the cover, unscrewed the blue screw, slid drive towards the front)
2. Opened up my WD External USB drive case (runs on a 2.5" HDD)
3. Plugged the PS3 HDD into the USB case, and plugged it into my PC.
4. Ran the diskmgmt.msc from the Windows RUN in the START Menu
5. Once the drive came up, I had to right-click on it and initialize it, this gave it a drive letter.
6. Then I downloaded this little app : (
http://www.ridgecrop.demon.co.uk/dow...at32format.zip).
7. Extracted it, and ran the following command in a DOS prompt: fat32 format e: ***obviously replacing the e: with the drive letter you saw in the disk management window.
8. Plugged the HDD back into the Ps3, and it formatted it to it's filesystem, and all was well.