device that *thinks* to be a spare...

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Yersterday i toubled with system crash due to an md device that stopped due
to an error on a single block (sata controller).

Starting from a live rescue cd to analize the situation I found that the
array thought the good disk was the one had the block failure, so
that reconstruction arrived at 75% and then restarted (I saw that
happending).

I eliminated the bad disk and the other couldn't start complaining it was a
spare one (but no one was configured as spare...) so that there where no
good disk. I had to turn it into a normal /dev/sda disk to be able to start
the system. 

My question is if there is a way to convince a device that it is the good
device w/o destroying the array and how it can happen that an array
component turns into a spare one.

What should I have one?

TIA
sandro
*:-)
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