If you have shell access to your empeg the fastest way is via a direct drive to drive copy.

But: You have to familiar with Linux/shell prompt and know how to get a shell prompt via the serial port - so you need that all working.

Assuming you do then this should do the trick. But, this method worked for me to move all songs/files from drive1 to drive0 on my 2 drive 60GB unit. Admittedly I only had about 7 GB on the second drive so it only took a few hours.

0. Get a shell prompt on your system via the com port. [this involves quiting/stopping the player program - the FAQ has info on this.

1. At the shell prompt enter this command to mount the drives read/write

rwm

2. Enter this command exactly as shown: (Cut and paste is your friend here :-)) )

(cd /drive1;tar cf - fids) | (cd /drive0;tar xf -)

[Nothing will show but your disks should start running, any errors equal bad news - you may see some if files cannot be copied across due to bad sectors on your drive1, it may take time to complete [expect it to take hours not minutes].
The copy may stop in this case - you will be able to restart the copy again(just enter the same ocmmand again) - the copy may fail [one or more time] if you disk is really near the end of its life.

You just have to keep trying - cooling the drive before the copy starts can help [stick the drive/empeg in the fridge beforehand if you find the drive works best from cold]. Protect the unit from moisture though!!!
YMMV - I have got data of drives that way by putting them in the freezer compartment while the drive is running (using long drive cables) - you'd be amazed sometimes what unreadable drives can be read that way.
Of course you must keep the ice [and melting ice] away from the electronics or bad karma will occur.

After copy completes:

3. Enter at the shell prompt: (cut'n'Paste recommended here too):

cd /empeg/var ; rwm ; rm tags database playlists

4. exit the shell /command prompt.

exit

[Player software will now resume]

5. Run Emplode and connect to the unit - it should force a rebuild of the database, with all songs as they were except now in the one drive.

6. Verify that your empeg is working properly

7. Remove the old failing disk from your system (follow the procedures in the FAQ for this). And/or return whole unit if under warranty.