When I upgraded my A31p to a 320Gb drive, here's what worked for me. I used a NTFS formatted external USB drive as a temp area. I used Acronis True Image to take a full image of the internal drive and put the image file on the external drive. Then I replaced the internal drive with the larger one, and restored from the image file, while allowing Acronis to enlarge the Windows partition. I did this twice, once for a 60 to 120 upgrade, and later from 120 to 320. In my case, I had to use a PC card USB 2.0 adapter to get the speed up. You shouldn't have that problem with an X40. I found that there were IBM disk formatting peculiarities that prevented a disk to disk clone with both disks outside the system, and I didn't have an Ultrabay adapter for the second drive, so I couldn't get them both inside the system. Not sure if an X40 has that issue either.
In your case, it sounds like the Passport and Powersuite would duplicate what I did, but I am not familiar with Powersuite. Lately, I've been using Clonezilla
which is free, but it has its quirks.
I loathe complete reinstalls...