Hopefully this will be of help to you. I just upgraded my archos 5 250gb to a crucial m4 128gb SSD that I had (I know it is less storage but the 250gb drive had just crapped out and I already had an extra m4). I believe that any sata drive will work as long as it is physically the same size or smaller then the drive currently in the archos, tho I did not try a larger capacity drive. Key is having the patched firmware running on the archos before you try to swap out the drives. The patched firmware removes the drive serial number check from the archos bootup.
Steps I took to do this were as follows:
Step 1 was to load a patched firmware. I used v1.6.54-patched (luckily I did this before the drive crapped out)https://sites.google.com/site/archos5imt/patched-fw
had the procedure for loading the patched firmware
Step 2 used the tear down guild to swap the hard driveshttps://sites.google.com/site/archos5im ... b-teardown
hint on removing the screen, there is a long white connector with a black bar on the top where the ribbon cable goes into. You need to pry the black bar up from the ribbon cable side. The bar rotates and relieves pressure from the cable so it can slide out.
The new hard drive needs to be the same physical size or smaller as the drive that you are replacing.
Make sure you move the bars from the side of the old hard drive to the new one (mine had allen head cap screws holding the bars on, not sure what size).
Step 3 reverse the tear down steps to put the unit back together
I put it back together to the point where the screen was connected to the white connector.
Step 4 I then powered the unit on holding the up volume button
Step 5 I then used volume buttons to select format drive
Step 6 I then hooked it up to a computer and moved the firmware-a57-1.6.54-patched.aos file to the main directory
I got the file from: http://archos.g3nius.org/index.php/Arch ... re_Updates
use the full firmware version and then rename the file to firmware-a57-1.6.54-patched.aos
Step 7 selected done then the archos updated the software
Step 8 the archos was now fully functional
Step 9 finished putting the archos back together
Step 10 moved music files back onto archos and enjoy.