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Use a bootable CD (e.g. SystemRescueCd from http://www.sysresccd.org/Main_Page and use `cp --archive SOURCE DEST` to copy the root partion of your old hd to the new one. After that you mayby have to adjust your /etc/fstab, /etc/lilo.conf on the new hd and finaly you have to run `/sbin/lilo -r <mount point of your new hd>`.
Check the connections for the HD making noises and make sure your pc power supply is not going bad. I have ended up with ps that go bad because of poor quality or wild surges in power inspite of surge protection. Luckily good PSs are available and a good investment.
SMART disk check old HD(if it is enabled) can tell you if HD is going bad. Good luck.