Your error output looks just like what I got on my screen when I just removed the disk. Did you try removing it from the arrays first? Basically warm-swap. Google suggests one or two people have tried it. John - To unsubscribe from this list: send the line "unsubscribe linux-raid" in the body of a message to majordomo@xxxxxxxxxxxxxxx More majordomo info at http://vger.kernel.org/majordomo-info.html