After some more testing it seems the problems with --incremental are more deep and general. I have found two steps that both appear to do the wrong thing: mdadm /dev/md0 --fail /dev/sdb mdadm /dev/md0 --remove /dev/sdb At this point mdadm -E /dev/sda shows that sdb has been removed, but mdadm -E of /dev/sdb shows both disks are active and in sync still. The metadata of sdb should be updated when failed or removed if possible. mdadm --incremental /dev/sdb This goes ahead and adds the disk back to the array, despite the fact that it has been explicitly removed. Whether or not the superblock on sdb is updated when it is removed, --incremental should NOT use it as long as mdadm -D /dev/md0 says that disk is removed, at least not use it in /dev/md0. -- 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