That may be the case, although I'm unsure how to scan the boot sector for errors and fix them. It's been my (limited) experience that once the boot sector on a standard HD gets errors or corrupts it's a done deal and the OS won't boot until those files are recompiled and/or repaired manually via a boot disk or similar means. The HDD FAQ sticky mentions that the system OS is embedded in flash memory and not on the HD, so if that's the case that leads me to think that this is not a bad sector on the cylinder issue because the OS does not boot or run from the HD. Of course that just begs the question, if the system doesn't run from the HD why doesn't it boot from the embedded memory?
But, until I know for sure that the internal temperature sensor is not preventing the units from starting properly I'd hate to waste $150 for a HD that is just going to freeze based on that sensor's output. From a logic standpoint, it just makes sense to me that they put that sensor in there so that the unit knows if it's safe to start or not.