Have you exhaustively tested your drives as well? The smartctl -t long test is a good one to start with. If you fail it sometimes re-writing the sector(s) in the area of the failure allow the drive to resolve the problem by using one of the space sectors (the drive hides a handful of from normal use and keeps them in reserve for just such occasions). However I recently had a drive I had to pull out and use the manufacturer's utility to 'zero' (erase/wipe) everything; it then finally passed a similar test within the drive utility. I expect it to resync without further issue. -- 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