Trouble adding disk to degraded array

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I recently had mdadm mark a disk in my RAID5-array as faulty. As it
was within warranty, I returned it to the manufacturer, and have now
installed a new drive. However, when I try to add it, recovery fails
about halfway through,  with the newly added drive being marked as a
spare, and one of my other drives marked as faulty!

I seem to have full access to my data when assembling the array
without the new disk using --force, and e2fsck reports no problems
with the filesystem.

What is happening here?
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