Hi Benjamin,
Welcome to Apple Discussions.
What are the performance differences between a 4200, 5400, and 7200 speed HD?
Soon after the 7200's first hit the market, I saw a good review of 9 or 10 drives, with a few of each speed. Results showed a much bigger speed improvement going from 4200 to 5400, than from 5400 to 7200; what the actual numbers are, I don't recall.
If I opt for the less expensive 4200 will I actually notice the difference in cpu speed and file access times if not using performance-heavy software?
I notice the difference between 35 and 45MPH going down the road without looking at the speedometer. Three out of the four others in the car could not. Will you notice the difference? Hard to say, but it will be there. Most users consider it significant.
Will the 4200 put off less heat?
This is drive dependent. Due to improving technology, some newer/faster drives actually run the same temp or cooler than older drives (FDB: Fluid Dynamic Bearings).
Will a 4200, since it is operating at a lower performance rate (true?) last longer than a faster HD?
Interesting question, but again, newer technology . . . the last time I checked (maybe a little less than a year ago?), then "current" faster (5400/7200) drives had the same MTBF (Mean Time Between Failures) specs as older 4200 drives.
What's the biggest size internal drive a Tibook can handle? Is there a limit?
Unless they've very recently come out with something bigger, 120GB is the largest 2.5" HD made, and the TiBook will handle it.
What's the best way to transfer all my data to the new drive from the old one?
Run Repair Disk, Repair Permissions, Background Maintenance, and use an app such as Carbon Copy Cloner or Super Duper to clone your entire HD to an external source, then install new HD and clone old HD back.
Another option is to buy an external HD enclosure, install your old HD in it, and clone it back to your new HD.
Lastly, are there brands/manufacturers that I should look out for?
Opinions will vary widely on that. Is Ford or Chevy or Chrysler better? Toyota or Honda or Subaru?