Wrong array size detected after reboot

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Hi guys,

After a reboot mdadm detects a much too small size for a raid5 array.
The array is part of a lvm volume group, which fails because the
device mapper notices that the physical volume is too small for the
volume group. At the moment I can't access any data.

What I did:

Array consisted of 3x 1.5TB disks.
After a disk failure a replaced the disks one by one with 3TB disks.
Resized array, volume group and partition to the new size according to
these instructions: https://raid.wiki.kernel.org/index.php/Growing

Everything went fine the array's up and running for a couple of months.
I believe this is the first reboot since.

I'm at a complete loss as what to do now. Any help is greatly appreciated.

Here's the kern.log (I don't remember the misaligned warning, when I
replaced the disks):
Sep  7 19:09:43 fandango kernel: [    3.259374] raid5: device sde1
operational as raid disk 2
Sep  7 19:09:43 fandango kernel: [    3.259378] raid5: device sdd1
operational as raid disk 1
Sep  7 19:09:43 fandango kernel: [    3.259380] raid5: device sdb1
operational as raid disk 0
Sep  7 19:09:43 fandango kernel: [    3.259727] raid5: allocated 3228kB for md2
Sep  7 19:09:43 fandango kernel: [    3.259764] raid5: raid level 5
set md2 active with 3 out of 3 devices, algorithm 2
Sep  7 19:09:43 fandango kernel: [    3.259766] RAID5 conf printout:
Sep  7 19:09:43 fandango kernel: [    3.259768]  --- rd:3 wd:3
Sep  7 19:09:43 fandango kernel: [    3.259770]  disk 0, o:1, dev:sdb1
Sep  7 19:09:43 fandango kernel: [    3.259771]  disk 1, o:1, dev:sdd1
Sep  7 19:09:43 fandango kernel: [    3.259773]  disk 2, o:1, dev:sde1
Sep  7 19:09:43 fandango kernel: [    3.259781] md2: Warning: Device
sde1 is misaligned
Sep  7 19:09:43 fandango kernel: [    3.259783] md2: Warning: Device
sdd1 is misaligned
Sep  7 19:09:43 fandango kernel: [    3.259785] md2: Warning: Device
sdb1 is misaligned
Sep  7 19:09:43 fandango kernel: [    3.259806] md2: detected capacity
change from 0 to 1603139141632
Sep  7 19:09:43 fandango kernel: [    3.261439]  md2: unknown partition table
Sep  7 19:09:43 fandango kernel: [    3.409802] device-mapper: table:
252:2: md2 too small for target: start=384, len=11721064448,
dev_size=3131131136

mdadm:
/dev/md2:
        Version : 00.90
  Creation Time : Wed Apr 29 23:31:24 2009
     Raid Level : raid5
     Array Size : 1565565568 (1493.04 GiB 1603.14 GB)
  Used Dev Size : 782782784 (746.52 GiB 801.57 GB)
   Raid Devices : 3
  Total Devices : 3
Preferred Minor : 2
    Persistence : Superblock is persistent

    Update Time : Fri Sep  7 21:30:40 2012
          State : clean
 Active Devices : 3
Working Devices : 3
 Failed Devices : 0
  Spare Devices : 0

         Layout : left-symmetric
     Chunk Size : 64K

           UUID : bbc76518:54235173:67388cd8:6b8a4141 (local to host fandango)
         Events : 0.16232920

    Number   Major   Minor   RaidDevice State
       0       8       17        0      active sync   /dev/sdb1
       1       8       49        1      active sync   /dev/sdd1
       2       8       65        2      active sync   /dev/sde1


The size is much too small. It should be around 6TB not 1.5TB.
Interestingly enough, the Array Size / Used Dev Size ratio seems to be correct.

Many Thanks!

Regards,
Markus
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