Greetings, I've got a RAID5 array running on 4 PATA IDE drives on a linux 2.6.15 kernel which has had a drive go out. When I replace the drive and force a re-assembly a rebuild starts but at a certain point through the rebuild an uncorrectable error occurs on another disk and kicks the 2nd disk out. This occurs at the same LBA every time. I am wondering what some suggestions are for getting my data off the array without causing the particular LBA to be read on the 2nd disk thats got a problem. Is there a way to assemble an array that has a disk replaced without causing a rebuild and if so, is there a way to keep the array read-only so that I minimize the chance of another error occurring while I'm pulling data off (or does it really matter?). I figure if I could mount the array in the safest way possible with three disks out of 4 I can copy data off the array avoiding to copy the file(s) that exist at the particular LBA causing the issue (by trial and error). Below are the messages from syslog showing the failure that occurs during the rebuild. I assume there is nothing else I can do about getting around this error? login as: root root@nas2's password: Last login: Sat May 26 15:25:01 2007 from darwin.home.harvey [root@nas2 ~]# tail -f /var/log/messages May 26 15:26:45 nas2 kernel: RAID5 conf printout: May 26 15:26:45 nas2 kernel: --- rd:4 wd:3 fd:1 May 26 15:26:45 nas2 kernel: disk 0, o:1, dev:hde1 May 26 15:26:45 nas2 kernel: disk 1, o:1, dev:hdf1 May 26 15:26:45 nas2 kernel: disk 2, o:1, dev:hdg1 May 26 15:26:45 nas2 kernel: disk 3, o:1, dev:hdh1 May 26 15:26:45 nas2 kernel: md: syncing RAID array md0 May 26 15:26:45 nas2 kernel: md: minimum _guaranteed_ reconstruction speed: 1000 KB/sec/disc. May 26 15:26:45 nas2 kernel: md: using maximum available idle IO bandwidth (but not more than 200000 KB/sec) for reconstruction. May 26 15:26:45 nas2 kernel: md: using 128k window, over a total of 292969216 bl ocks. May 26 15:26:45 nas2 kernel: md: syncing RAID array md0 May 26 15:26:45 nas2 kernel: md: minimum _guaranteed_ reconstruction speed: 1000 KB/sec/disc. May 26 15:26:45 nas2 kernel: md: using maximum available idle IO bandwidth (but not more than 200000 KB/sec) for reconstruction. May 26 15:26:45 nas2 kernel: md: using 128k window, over a total of 292969216 blocks. ... May 26 18:09:05 nas2 kernel: hdh: dma_intr: status=0x51 { DriveReady SeekComplete Error } May 26 18:09:05 nas2 kernel: hdh: dma_intr: error=0x40 { UncorrectableError }, LBAsect=385347135, high=22, low=16248383, sector=385347103 May 26 18:09:05 nas2 kernel: ide: failed opcode was: unknown May 26 18:09:05 nas2 kernel: end_request: I/O error, dev hdh, sector 385347103 May 26 18:09:05 nas2 kernel: raid5: read error not correctable. May 26 18:09:05 nas2 kernel: raid5: Disk failure on hdh1, disabling device. Operation continuing on 2 devices May 26 18:09:07 nas2 kernel: hdh: dma_intr: status=0x51 { DriveReady SeekComplete Error } May 26 18:09:07 nas2 kernel: hdh: dma_intr: error=0x40 { UncorrectableError }, LBAsect=385347135, high=22, low=16248383, sector=385347111 May 26 18:09:07 nas2 kernel: ide: failed opcode was: unknown May 26 18:09:07 nas2 kernel: end_request: I/O error, dev hdh, sector 385347111 May 26 18:09:07 nas2 kernel: raid5: read error not correctable. May 26 18:09:09 nas2 kernel: hdh: dma_intr: status=0x51 { DriveReady SeekComplete Error } May 26 18:09:09 nas2 kernel: hdh: dma_intr: error=0x40 { UncorrectableError }, LBAsect=385347135, high=22, low=16248383, sector=385347119 May 26 18:09:09 nas2 kernel: ide: failed opcode was: unknown May 26 18:09:09 nas2 kernel: end_request: I/O error, dev hdh, sector 385347119 May 26 18:09:09 nas2 kernel: raid5: read error not correctable. May 26 18:09:11 nas2 kernel: hdh: dma_intr: status=0x51 { DriveReady SeekComplete Error } May 26 18:09:11 nas2 kernel: hdh: dma_intr: error=0x40 { UncorrectableError }, LBAsect=385347135, high=22, low=16248383, sector=385347127 May 26 18:09:11 nas2 kernel: ide: failed opcode was: unknown May 26 18:09:11 nas2 kernel: end_request: I/O error, dev hdh, sector 385347127 May 26 18:09:11 nas2 kernel: raid5: read error not correctable. May 26 18:09:13 nas2 kernel: hdh: dma_intr: status=0x51 { DriveReady SeekComplete Error } May 26 18:09:13 nas2 kernel: hdh: dma_intr: error=0x40 { UncorrectableError }, LBAsect=385347135, high=22, low=16248383, sector=385347135 May 26 18:09:13 nas2 kernel: ide: failed opcode was: unknown May 26 18:09:13 nas2 kernel: end_request: I/O error, dev hdh, sector 385347135 May 26 18:09:13 nas2 kernel: raid5: read error not correctable. May 26 18:09:13 nas2 kernel: md: md0: sync done. May 26 18:09:13 nas2 kernel: RAID5 conf printout: May 26 18:09:13 nas2 kernel: --- rd:4 wd:2 fd:2 May 26 18:09:13 nas2 kernel: disk 0, o:1, dev:hde1 May 26 18:09:13 nas2 kernel: disk 1, o:1, dev:hdf1 May 26 18:09:13 nas2 kernel: disk 2, o:1, dev:hdg1 May 26 18:09:13 nas2 kernel: disk 3, o:0, dev:hdh1 May 26 18:09:13 nas2 kernel: RAID5 conf printout: May 26 18:09:13 nas2 kernel: --- rd:4 wd:2 fd:2 May 26 18:09:13 nas2 kernel: disk 0, o:1, dev:hde1 May 26 18:09:13 nas2 kernel: disk 2, o:1, dev:hdg1 May 26 18:09:13 nas2 kernel: disk 3, o:0, dev:hdh1 May 26 18:09:13 nas2 kernel: RAID5 conf printout: May 26 18:09:13 nas2 kernel: --- rd:4 wd:2 fd:2 May 26 18:09:13 nas2 kernel: disk 0, o:1, dev:hde1 May 26 18:09:13 nas2 kernel: disk 2, o:1, dev:hdg1 May 26 18:09:13 nas2 kernel: disk 3, o:0, dev:hdh1 May 26 18:09:13 nas2 kernel: RAID5 conf printout: May 26 18:09:13 nas2 kernel: --- rd:4 wd:2 fd:2 May 26 18:09:13 nas2 kernel: disk 0, o:1, dev:hde1 May 26 18:09:13 nas2 kernel: disk 2, o:1, dev:hdg1 Thanks for any advice. 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