I have a RAID5 array consisting of 4 drives that recently had a problem. One of the drives 'removed' itself from the array and when I added it back it started the background rebuilding I expected, however I then noticed from smartctl that the drive was showing 'imminent failure' due to 3300+ reallocated sector errors. At this stage I decided I wanted to pull the drive before it finished the rebuild and replace it. However after I stopped the array using:- mdadm --stop /dev/md126 I was unable to put that drive into fail status mdadm --fail /dev/sdj1 No Such Device At this stage I decided to leave the array offline till I had a replacement drive available to slot in. I now have the replacement drive and as I was unable to either fail or remove the offending drive I decided to do a physical pull of the drive, reboot the machine to show the drive remove and then a second reboot with the new blank drive available. This seems to have partially worked in that mdadm -D /dev/md126 /dev/md126: Version : 1.2 Creation Time : Sat Aug 6 01:24:12 2011 Raid Level : raid5 Used Dev Size : 1953512960 (1863.02 GiB 2000.40 GB) Raid Devices : 4 Total Devices : 3 Persistence : Superblock is persistent Update Time : Sun Aug 7 05:23:45 2011 State : active, degraded, Not Started Active Devices : 3 Working Devices : 3 Failed Devices : 0 Spare Devices : 0 Layout : left-symmetric Chunk Size : 512K Name : MY_NEW_RAID UUID : herro_this_isnt_needed Events : 36003 Number Major Minor RaidDevice State 0 8 129 0 active sync /dev/sdi1 1 0 0 1 removed 2 8 161 2 active sync /dev/sdk1 3 8 177 3 active sync /dev/sdl1 Which is what I expected to see. However I cannot add the replacement drive into the array. ~ >:mdadm --add /dev/md126 /dev/sdj1 mdadm: add new device failed for /dev/sdj1 as 4: Invalid argument ~ >:mdadm --add --force /dev/md126 /dev/sdj1 mdadm: set device faulty failed for /dev/sdj1: No such device ~ >:mdadm --re-add /dev/md126 /dev/sdj1 mdadm: --re-add for /dev/sdj1 to /dev/md126 is not possible and even more confusingly ~ >:mdadm -E /dev/sdj1 /dev/sdj1: Magic : a92b4efc Version : 1.2 Feature Map : 0x0 Array UUID : not needed Name : My_NEW_RAID Creation Time : Sat Aug 6 01:24:12 2011 Raid Level : raid5 Raid Devices : 4 Avail Dev Size : 3907027053 (1863.02 GiB 2000.40 GB) Array Size : 11721077760 (5589.05 GiB 6001.19 GB) Used Dev Size : 3907025920 (1863.02 GiB 2000.40 GB) Data Offset : 2048 sectors Super Offset : 8 sectors State : active Device UUID : not needed Update Time : Sun Aug 7 05:23:45 2011 Checksum : 6172254 - correct Events : 0 Layout : left-symmetric Chunk Size : 512K Device Role : spare Array State : AAAA ('A' == active, '.' == missing) Could someone possibly point me in the right direction as to what I'm doing wrong? Thanks in advance. -- 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