raid10 devices all marked as spares?!

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Hi list,

I'm sorry if this is the wrong place to start, but I've been quite lost as to what is going wrong here.

I've been having some issues latly with my raid10 array. First some info.

I have three raid10 arrays on my gentoo box on 2 drives using GPT.
I was running 3.2.1 at the time but have 3.4.0 running at the moment.
mdadm - v3.2.5 - 18th May 2012


md0, a 2 far-copies, 1.2 metadata, raid10 array consisting of /dev/sda4 and sdb4. md1, a 2 offset-copies, 1.2 metadata, raid10 array consisting of /dev/sda5 and sdb5 md2, a 2 offset-copies, 1.2 metadata, raid10 array consisting of /dev/sda6 and sdb6

sd*1 is bios_grub data, sd*2 is 256mb fat for playing with uefi and sd*3 is 8gigs of unused space, may have some version of ubuntu on it and sd*7 for swap.

For all of this, md0 has always worked normally. it is being assembled from initramfs where a static mdadm lives as such:
/bin/mdadm -A /dev/md0 -R -a md /dev/sda4 /dev/sdb4 || exit 1

md1 and md2 are being brought up during boot, md0 holds root, /usr etc wheras md1 are just for home and data.

The last few weeks md1 and md2 randomly fail to come up properly. md1 or md2 come up as inactive and one of the two drivers are marked as spares. (Why as spares? Why won't it try to run the array with a missing drive?) While this happens, it's completly abitrary whether sda or sdb is being used. so md1 can be sda5[2](S) and md2 can be sdb5[2](S).

When this happens, I mdadm --stop /dev/md1 and /dev/md2, followed immediatly by mdadm -A /dev/md1 (using mdadm.conf which doesn't even list the devices. ARRAY /dev/md1 metadata=1.2 UUID=nnn name=host:home). The arrays come up and work just fine.

What happend today however, is that md2 again does not come up, and sda6[3](S) shows in /proc/mdadm. However re-assembly of the array fails and only using mdadm -A /dev/md2 /dev/sda6 /dev/sdb6 shows: mdadm: device 1 in /dev/md2 has wrong state in superblock, but /dev/sdb6 seems ok mdadm: /dev/md2 assembled from 0 drives and 2 spares - not enough to start the array.
/proc/mdadm shows as somewhat expected.
md2 : inactive sda6[3](S) sdb6[2](S)

Only using sdb6 however also fails. I guess because it does not want to use a spare.
mdadm: failed to RUN_ARRAY /dev/md2: Invalid argument
mdadm: Not enough devices to start the array.

Now the really disturbing part comes from mdadm --examine.
valexia oliver # mdadm --examine /dev/sda6
/dev/sda6:
          Magic : a92b4efc
        Version : 1.2
    Feature Map : 0x0
     Array UUID : nnnn
           Name : host:opt  (local to host host)
  Creation Time : Sun Aug 28 17:46:27 2011
     Raid Level : -unknown-
   Raid Devices : 0

 Avail Dev Size : 456165376 (217.52 GiB 233.56 GB)
    Data Offset : 2048 sectors
   Super Offset : 8 sectors
          State : active
    Device UUID : nnnn

    Update Time : Mon May 28 20:52:35 2012
       Checksum : ac17255 - correct
         Events : 1


   Device Role : spare
   Array State :  ('A' == active, '.' == missing)

sdb6 lists identical content only with the checksum's being correbt, albeit different and of coruse the Device UUID. Array UUID is of course identical as is creation time.

Also to note, is that grub2 does mention an 'error: Unsupported RAID level: -1000000.' which probably relates to the 'Raid Level: -unknown-'.

As to what may have caused this? I have absolutely no idea. I did a clean shutdown where the arrays get cleanly unmounted. Not 100% sure if the arrays get --stopped but I would be surprised if they did not.

So I guess is this a md driver bug? Is there anything I can do to recover my data, which i cannot image it not being?

Thanks in advance for reading this.

Oliver
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