Hi Neil, I see the following issue: if more than one stripe-head experiences an error in raid5_end_write_request, then when first stripe-head is handled, it eventually fails the disk, but when the second stripe-head is handled, disk is already marked as Faulty, so R5_WriteError is not cleared from this second stripe-head, but it still remains in the stripe cache. Below are more details on the flow. I added some prints to display the flags values etc. # raid6 is rebuilding a disk # disk fails, as a result, raid5_end_write_request is called on two stripe-heads: [23369]md48066*[raid5_end_write_request:2002] sh[4560].flags=0x101A dev[0].flags=0x20003 rdev[dm-6].flags=0x40 bio=ffff880028744fd8[4592(4560):8] WRITE ERROR [13527.467363] [3842]md48066*[raid5_end_write_request:2002] sh[4568].flags=0x101B dev[0].flags=0x20003 rdev[dm-6].flags=0x240 bio=ffff880028742bc0[4600(4568):8] WRITE ERROR As a result, appropriate r5dev's are marked with R5_WriteError on these two stripe-heads. # raid5 calls analyse_stripe on behalf of stripe-head 4560 ((through handle_active_stripes->handle_stripe->analyse_stripe) # analyse_stripe performs this code: if (rdev && test_bit(R5_WriteError, &dev->flags)) { /* This flag does not apply to '.replacement' * only to .rdev, so make sure to check that*/ struct md_rdev *rdev2 = rcu_dereference( conf->disks[i].rdev); if (rdev2 == rdev) clear_bit(R5_Insync, &dev->flags); if (rdev2 && !test_bit(Faulty, &rdev2->flags)) { s->handle_bad_blocks = 1; it clears the R5_WriteError and sets handle_bad_blocks on the stripe-head # handle_stripe performs: if (s.handle_bad_blocks) for (i = disks; i--; ) { struct md_rdev *rdev; struct r5dev *dev = &sh->dev[i]; if (test_and_clear_bit(R5_WriteError, &dev->flags)) { /* We own a safe reference to the rdev */ rdev = conf->disks[i].rdev; if (!rdev_set_badblocks(rdev, sh->sector, STRIPE_SECTORS, 0)) md_error(conf->mddev, rdev); this marks the rdev as Faulty and fails it (bad blocks are disabled) # raid5d calls analyse_stripe on stripe-head 4568. However, rdev is already marked as Faulty, so it does: if (rdev && test_bit(Faulty, &rdev->flags)) rdev = NULL; and later this condition does not hold: if (rdev && test_bit(R5_WriteError, &dev->flags)) { so R5_WriteError is not cleared, but this stripe-head is still valid in the stripe cache. Dumping the state of this stripe-head in the stripe-cache (through custom sysfs entry): sh[4568].state=0x1010 disks=5 pdidx=2 qdidx=3 dev[0].flags=0x20001 rdev[???].flags=0x0 (sector=13688) dev[1].flags=0x11 rdev[dm-7].flags=0x2 (sector=13720) dev[2].flags=0x11 rdev[dm-8].flags=0x2 (sector=0) *P* dev[3].flags=0x11 rdev[dm-9].flags=0x2 (sector=0) *Q* dev[4].flags=0x11 rdev[dm-10].flags=0x2 (sector=13656) # Now user recovers the disk and re-adds the disk back into the array. Rebuild starts, and eventually md_do_sync calls sync_request on this stripe-head, which calls handle_stripe->analyse_stripe. Now analyse_stripe sees the stale R5_WriteError flag and fails the disk, which aborts the rebuild. Here is the stack trace, which detects the stale R5_WriteError and fails the disk: [<ffffffffa02d4543>] error+0x153/0x1d0 [raid456] [<ffffffffa0445449>] md_error.part.39+0x19/0xa0 [md_mod] [<ffffffffa0445503>] md_error+0x33/0x60 [md_mod] [<ffffffffa02da07c>] handle_stripe+0x57c/0x2250 [raid456] [<ffffffffa02dcacb>] sync_request+0x18b/0x390 [raid456] [<ffffffffa044320c>] md_do_sync+0x76c/0xda0 [md_mod] [<ffffffffa044084d>] md_thread+0x10d/0x140 [md_mod] Does this analysis make sense? I don't know how to fix issue though. I am looking at kernel (3.8.13 - as usual), but looking at your for-linus branch, it seems like the same would happen. Thanks, Alex. -- 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