How do I remove bad144 from my pre-4.X system so I can upgrade safely?

Use disklabel -e -rwd0 to edit the disklabel in place. Just remove the word badsect from the flags field, save, and exit. The bad144 file will still take up some space on your drive, but the disk itself will be usable.

We still recommend you purchase a new disk if you have a large number of bad blocks.
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