Bad news: Jansen's solution seems to delay the problem, but not fix it
for me.

I got a new 500GB drive which dies when I try this:

# mke2fs -c /dev/sda1

The block at which it dies depends on whether I run a kernel with Jansen's 
suggestion or not.
With USB_EHCI_SPLIT_ISO, USB_EHCI_ROOT_HUB_IT or USB_EHCI_TT_NEWSCHED enabled 
and USB_BANDWITH disabled, it dies pretty soon.
On the other hand, when USB_EHCI_SPLIT_ISO, USB_EHCI_ROOT_HUB_IT and 
USB_EHCI_TT_NEWSCHED are disabled and USB_BANDWITH is enabled, it takes
as much as 10 times longer for the USB connection to die, but it dies at the 
end all the same.

It is definitely a bug in the handling of USB controllers. I gathered some 
evidence that this is the case using a different machine and a 300 GB disk. I 
have two different generic
USB enclosures. The same disk mounted on one of them works perfectly, while 
mounted on the other it exhibits the connection problems and eventually dies.

Finally, a caveat: Creating a partition in the 500GB disk without badblock 
checking worked fine. I could also copy some large movie files into the disk, 
but when it eventually died,
it killed the partition. The data in the disk was totally destroyed and I could 
not recover it. Maybe this is a particularly bad controller (reported as 
"Samsung" by sysfs) but the
severing of the USB bus connection should never have the effect of totally 
destroying all the data stored in a device. Too bad.

-- 
USB mass storage stops working after a while
https://bugs.launchpad.net/bugs/61235
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