Re: 4540 Mfp - Disk dead. New disk installed - erase and unlock/lock to device not available.

This is all I can find and it seems you have tried them all. But I will post.

99.09.63 – Incorrect Disk

This error indicates the expected encrypted HDD is not present. This is expected behavior when installing a new HDD in a device where the previous HDD was encrypted.

Resolution

Perform the following actions from the Preboot Menu under the “Administrator” option:
1.Clear disk password.

2.Download, Option - USB Thumb drive (download firmware).

3.If the error persists, perform an Erase/Unlock procedure then Download, Option - USB Thumb drive (download firmware).