Unable to re-add a disk after a reboot.

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Hi,

I just finished converting a 3-disk raid5 to 4-disk raid6. After a reboot to start clean, I noticed that one of the disk (the new one I just added) was missing in /proc/partitions. This was disk 4 in my /dev/md0. Assuming some cable issue, I powered off, wiggled the cables and restarted and the device was found by kernel. However, md0 shows device missing and array degraded

   lata [rramesh] 280 > cat /proc/mdstat
   Personalities : [raid6] [raid5] [raid4]
   md0 : active raid6 sdb1[0] sdd1[3] sdc1[1]
          3906763776 blocks super 1.2 level 6, 512k chunk, algorithm 2
   [4/3] [UUU_]

   unused devices: <none>

However my attempt to --re-add does not work.

   lata [rramesh] 277 > sudo mdadm /dev/md0 --verbose --re-add /dev/sde1
   mdadm: --re-add for /dev/sde1 to /dev/md0 is not possible
   lata [rramesh] 278 > sudo mdadm -E /dev/sde1
   /dev/sde1:
              Magic : a92b4efc
            Version : 1.2
        Feature Map : 0x0
         Array UUID : 730051d9:f4c58e0c:504fd1d9:798a84a4
               Name : lata:0  (local to host lata)
      Creation Time : Sun Oct  6 16:41:01 2013
         Raid Level : raid6
       Raid Devices : 4

     Avail Dev Size : 5860268943 (2794.39 GiB 3000.46 GB)
         Array Size : 3906763776 (3725.78 GiB 4000.53 GB)
      Used Dev Size : 3906763776 (1862.89 GiB 2000.26 GB)
        Data Offset : 262144 sectors
       Super Offset : 8 sectors
              State : clean
        Device UUID : 03898148:47c40cc2:f365082e:9f7f06cf

        Update Time : Thu Aug 14 08:53:16 2014
           Checksum : 346e9226 - correct
             Events : 1191488

             Layout : left-symmetric
         Chunk Size : 512K

       Device Role : Active device 3
       Array State : AAAA ('A' == active, '.' == missing)
   lata [rramesh] 279 > fgrep UUID /etc/mdadm/mdadm.conf
   # ARRAY /dev/md/0 metadata=1.2
   UUID=0e9f76b5:4a89171a:a930bccd:78749144 name=zym:0
   ARRAY /dev/md0 metadata=1.2 spares=1 name=lata:0
   UUID=730051d9:f4c58e0c:504fd1d9:798a84a4

I checked the SMART and it shows a lot of reallocated_sector_ct errors also. So, the disk is dying, but I am not able understand why mdadm would not add.

   SMART Attributes Data Structure revision number: 16
   Vendor Specific SMART Attributes with Thresholds:
ID# ATTRIBUTE_NAME FLAG VALUE WORST THRESH TYPE UPDATED WHEN_FAILED RAW_VALUE 1 Raw_Read_Error_Rate 0x000b 091 091 016 Pre-fail Always - 53 2 Throughput_Performance 0x0005 100 100 054 Pre-fail Offline - 0 3 Spin_Up_Time 0x0007 135 135 024 Pre-fail Always - 426 (Average 425) 4 Start_Stop_Count 0x0012 100 100 000 Old_age Always - 59 *5 Reallocated_Sector_Ct 0x0033 001 001 005 Pre-fail Always FAILING_NOW 330* 7 Seek_Error_Rate 0x000b 098 098 067 Pre-fail Always - 2 8 Seek_Time_Performance 0x0005 100 100 020 Pre-fail Offline - 0 9 Power_On_Hours 0x0012 100 100 000 Old_age Always - 3445 10 Spin_Retry_Count 0x0013 100 100 060 Pre-fail Always - 0 12 Power_Cycle_Count 0x0032 100 100 000 Old_age Always - 59 192 Power-Off_Retract_Count 0x0032 100 100 000 Old_age Always - 548 193 Load_Cycle_Count 0x0012 100 100 000 Old_age Always - 548 194 Temperature_Celsius 0x0002 153 153 000 Old_age Always - 39 (Min/Max 21/43) 196 Reallocated_Event_Count 0x0032 001 001 000 Old_age Always - 17604 197 Current_Pending_Sector 0x0022 001 001 000 Old_age Always - 13256 198 Offline_Uncorrectable 0x0008 100 100 000 Old_age Offline - 0 199 UDMA_CRC_Error_Count 0x000a 200 200 000 Old_age Always - 0

Any recommendations while I am waiting to get a replacement.

Ramesh

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