On Xbox make sure that you only attempt to download the expansion packs from the BF3 in game store, if you attempt to download them via XBL Marketplace it will charge you a second time.
Your first problem is that your HDD is too small unless you only play BF3 on your Xbox. Here's a breakdown of files for BF3, you may be able to delete some older updates:
Mandatory Files:
Battlefield 3 Title Update (Auto-Download) - 201 MB
Muiltiplayer Update 6 - 2.0 GB
Minimum HDD space require to play Multiplayer: 2.2 GB
DLC Specific files:
End Game - 1.8 GB
Aftermath - 1.6 GB
Armored Kill - 1.6 GB
Multiplayer Update 3 (Close Quarters) - 2.4 GB
Battlefield 3 Update (Back to Karkand) - 2.1 GB
HDD space required to play ALL the DLC: 9.5 GB
Optional files for better performance:
Battlefield 3 Disc 1 - 7.3 GB
Battlefield 3 HD Content - 1.5 GB
When you install your 60 GB HDD you will have to follow these steps in order to play BF3 online with all of your expansions again: You must go to your download history and re-download your online pass, your Premium file, any DLCs that you've bought such as dog tag packs or shotcut packs, and your expansions covered by Premium. Since you're on your computer it's easiest to log into the Xbox Live site at http://www.xbox.com/en-US/ and then go to "My Account" and then "Purchase History" and then scroll down until you see everthing that I just mentioned above and click "Add to Queue" and then the next time you log into your Xbox your queued items will automatically download to your Xbox.
Once evertything is completely downloaded start BF3. At this point when you reach the main title screen you will receive a series of pop ups stating that you now have each expansion. Now from the main menu go to multiplayer, open server browser and then open the server browser filter by clicking R3 and check all new maps and game modes or you won't find any games on the new expansions.
Now it's telling me it's assinged to another consol. I have only used this 1 Xbox. It's just a new hard drive.
I've seen this happen since I own two Xboxes. If you still have your Old HDD put it back in, log in with your XBL account, take a USB stick and copy the files to the USB stick. Then put your new HDD in, log in with your XBL account and transfer the files to your new HDD and you will be good to go. You can also transfer the rights to the DLC to your new console but I can't remember how to do that since I've only upgraded my HDD once in my 360 Slims.
