Hi, >> I've tried this, but it complains about the system not being shut down >> cleanly. Should I just force it? > > Check so that the event count is fairly ok on all components (doesn't differ > too much), and then --force it. It's not that you have much choice > currently, but that's a good sanity check. Thanks so much for your help. I've managed to add the new disk and make the whole array active. Took about 6hrs at 35MB/s to sync. I'm now copying all 1.5TB to a remote server and will rebuild it from scratch. Thanks again, Alex -- 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