ISTR that when a new HDD is manufactured, it is scanned to identify bad sectors (no manufacturing process is ever 100% efficient) by the manufacturer and they are then marked in firmware as unavailable.
If you start swapping PCB's over, that could be a problem if the bad sector list is actually stored in the PCB?
Same goes too if there are Grown bad sectors (the ones that appear during use) and SMART only reports failing hard disc when grown defects exceeds > N.