I experienced a total drive failure. Looking into it, I discovered that the particular hard drive model that failed is a particularly bad one. So I replaced not only the failed drive, but another of the same model. In the process, I ran into a problem where on reboot the RAID device was inactive. I finally found a solution to my problem in the earlier thread "raid5 reshape is stuck" that started on 15 May. By the way, I am on Fedora 21 > rpm -q mdadm mdadm-3.3.2-1.fc21.x86_64 > uname -srvmpio Linux 4.0.4-202.fc21.x86_64 #1 SMP Wed May 27 22:28:42 UTC 2015 x86_64 x86_64 x86_64 GNU/Linux The short version of the story is that I replaced the dead drive and let the raid5 partition rebuild. Then I added a new drive and let the partition rebuild. Then I removed the not-yet-dead drive and here is where I ran into the same problem as the other poster. Basically, I did this to replace the still-working-but-suspect device, after the partition completed rebuilding when I replaced the actually-dead drive: mdadm --manage /dev/md125 --add /dev/sdf1 mdadm --grow --raid-devices=5 /dev/md125 ... wait for the rebuild to complete mdadm --fail /dev/md125 /dev/sdd2 mdadm --remove /dev/md125 /dev/sdd2 mdadm --grow --raid-devices=4 /dev/md125 mdadm: this change will reduce the size of the array. use --grow --array-size first to truncate array. e.g. mdadm --grow /dev/md125 --array-size 118964736 mdadm --grow /dev/md125 --array-size 118964736 mdadm --grow --raid-devices=4 /dev/md125 ... this failed with a mysterious complaint about my first partition (Cannot set new_offset). Research got me to try: mdadm --grow --raid-devices=4 /dev/md125 --backup-file /root/md125.backup .... here everything ground to a halt. The reshape was at 0% and there was no disk activity. The solution was to edit /lib/systemd/system/mdadm-grow-continue@.service to look like this (it was important that the backup file was placed in /tmp and not in /root or anywhere else. SELinux allowed mdadm to create a file in /tmp by not anywhere else I tried): # This file is part of mdadm. # # mdadm is free software; you can redistribute it and/or modify it # under the terms of the GNU General Public License as published by # the Free Software Foundation; either version 2 of the License, or # (at your option) any later version. [Unit] Description=Manage MD Reshape on /dev/%I DefaultDependencies=no [Service] ExecStart=/usr/sbin/mdadm --grow --continue /dev/%I --backup-file=/tmp/raid-backup-file StandardInput=null #StandardOutput=null #StandardError=null KillMode=none I had to comment out the standard out and error lines to see why the service was failing. I was pulling out my hair. The raid device failed to initialize, so my computer dumped me into runlevel 1. When the process finished after the above fix, I ended up in a weird state: Number Major Minor RaidDevice State 0 8 2 0 active sync /dev/sda2 1 8 17 1 active sync /dev/sdb1 5 8 33 2 active sync /dev/sdc1 6 0 0 6 removed 6 8 49 - spare /dev/sdd1 but that is probably as a result of what I tried to bring it back. I could "stop" the raid and manually recreate it and the filesystems on it were fine. But it wouldn't come up without me doing that. I'm going to try to fail and re-add that disk again and see if it works now that it was able to complete a sync. I did a fail, remove, and add on /dev/sdd1 and it very quickly synced and came into service. The command "mdadm --detail /dev/md125" now shows a happy raid5 with four partitions in it, all "active sync" So all I had to do was add the --backup-file to the command to "grow" down to 4 devices, and also to mdadm-grow-continue@.service. I thought I'd let you know, in particular, that adding --backup-file=/tmp/raid-backup-file to the service file worked to get the process unstuck, and that due to SELinux it must be in tmp. Also, should the "Cannot set new_offset" complaint maybe suggest trying again with a backup file? Eddie -- 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