Re: Couldn't remove rebuilding drive from RAID5 rebuild, now can't add new drive to array?

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On 11/08/2011, Another Sillyname <anothersname@xxxxxxxxxxxxxx> wrote:
> 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.
>
Further to my earlier Message.....

I took the array offline again

mdadm --stop /dev/md126

and re-assembled it

mdadm --assemble /dev/md126 /dev/sd[i-l]1

and the array seems to be reconstructed but sdj1 isn't rebuilding....

I have attached the mdadm -E for the drives, can someone explain why
the three active drives are showing a missing drive from the array
while the spare is showing all 4 slots active?

Also what do I need to do to force the sdj1 to start it's rebuild?

~ >:mdadm -E /dev/sd[i-l]1
/dev/sdi1:
          Magic : a92b4efc
        Version : 1.2
    Feature Map : 0x0
     Array UUID : not_needed_matches_others
           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 : clean
    Device UUID : not_needed

    Update Time : Thu Aug 11 22:51:57 2011
       Checksum : 551e2ef7 - correct
         Events : 36006

         Layout : left-symmetric
     Chunk Size : 512K

   Device Role : Active device 0
   Array State : A.AA ('A' == active, '.' == missing)
/dev/sdj1:
          Magic : a92b4efc
        Version : 1.2
    Feature Map : 0x0
     Array UUID : not_needed_matches_others
           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)
/dev/sdk1:
          Magic : a92b4efc
        Version : 1.2
    Feature Map : 0x0
     Array UUID : not_needed_matches_others
           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 : clean
    Device UUID : not_needed_matches_others

    Update Time : Thu Aug 11 22:51:57 2011
       Checksum : a5145e39 - correct
         Events : 36006

         Layout : left-symmetric
     Chunk Size : 512K

   Device Role : Active device 2
   Array State : A.AA ('A' == active, '.' == missing)
/dev/sdl1:
          Magic : a92b4efc
        Version : 1.2
    Feature Map : 0x0
     Array UUID : not_needed_matches_others
           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 : clean
    Device UUID : not_needed_matchesothers

    Update Time : Thu Aug 11 22:51:57 2011
       Checksum : c269d59b - correct
         Events : 36006

         Layout : left-symmetric
     Chunk Size : 512K

   Device Role : Active device 3
   Array State : A.AA ('A' == active, '.' == missing)
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