I encountered the same problem as everybody on this topic: input/output error (5) when trying to format a new HD. The HD is a Samsung 1 TB, external USB. I tried to format it into 2 partitions, one with MS-DOS FAT32 formatting, the other with HFS+ [Mac] formatting. In disk utility this can't be done, but even basic formatting gave me the error mentioned.
This particular formatting can be done using Terminal, but even here I got the dreaded input/output error, no matter what type of formatting I tried. I am running 10.5.3 on a 2007 dual Core iMac btw. I turned to my old G4 running 10.3.9 and here it worked flawless. No error messgae, it did what I wanted and that was that. What struck me though is that Terminal commands have also changed over the years: some were no longer existing, others were slightly altered.
So my trick was using an old Mac. No jumper settings were possible on my disk, as it was a SATA with a IDE converter [to hook it up to my old USB enclosure]
Hope this helps someone !