degraded raid array with bad blocks

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Hi,
today I had some problems with my mdadm raid5 (4disks). Firstly I try to
explaine what happened and what the result is:

One disk in my array has some bad blocks. After some hardware-changes
one of the intact disks was thrown out of the array due to a faulty
sata-cable.
I shut down the server and replaced the cable.
After booting, the removed disk wasn't re added to the array (maybe
because of different event count). --re-add doesn't work.
So I used --add.

Because of the bad blocks on one of the remaining disks, the rebuild
stops when reaching the first bad block. The re added disk is declared
as spare, 2 disks active and the disk with bad blocks as faulty.

/dev/md127:
        Version : 1.2
  Creation Time : Tue Apr 19 08:51:32 2011
     Raid Level : raid5
     Array Size : 5860538880 (5589.05 GiB 6001.19 GB)
  Used Dev Size : 1953512960 (1863.02 GiB 2000.40 GB)
   Raid Devices : 4
  Total Devices : 4
    Persistence : Superblock is persistent

    Update Time : Thu Jul 16 19:02:09 2015
          State : clean, FAILED
 Active Devices : 2
Working Devices : 3
 Failed Devices : 1
  Spare Devices : 1

         Layout : left-symmetric
     Chunk Size : 512K

           Name : FiFa-Server:0
           UUID : 839fb405:d0b1f13a:5a55ee42:fc8a2061
         Events : 107223

    Number   Major   Minor   RaidDevice State
       0       0        0        0      removed
       1       8       80        1      active sync   /dev/sdf
       5       8       32        2      active sync   /dev/sdc
       6       0        0        6      removed

       4       8       96        -      faulty   /dev/sdg
       6       8       64        -      spare   /dev/sde


In my opinion there a 3 possibilities to get the array back working. I
am not sure whether both possibilities really exist and which one is the
most promising.
	- Using the 'spare'-disk as active disk. The data on the disk
	  should be still there.
	- Ignoring the bad blocks and loose information stored in this
	  blocks
	- force start the array without the 'spare' disk and copy the
	  data to backup-storage, or does the bad block will cause the
	  array to fail when reaching a bad block?

In the attachment you can find the output of --examine.
In can not explain why 3 disk have a Bad Block Log. According to
smart-values only sdg has Reallocated_Sector_Ct >0
Another thing I can't explain is why sdg (which is the disk with known
bad blocks) has a lower event count.


I hope I can get some great ideas how to fix my array.

Fabian

/dev/sdc:
          Magic : a92b4efc
        Version : 1.2
    Feature Map : 0x0
     Array UUID : 839fb405:d0b1f13a:5a55ee42:fc8a2061
           Name : FiFa-Server:0
  Creation Time : Tue Apr 19 08:51:32 2011
     Raid Level : raid5
   Raid Devices : 4

 Avail Dev Size : 3907027120 (1863.02 GiB 2000.40 GB)
     Array Size : 5860538880 (5589.05 GiB 6001.19 GB)
  Used Dev Size : 3907025920 (1863.02 GiB 2000.40 GB)
    Data Offset : 2048 sectors
   Super Offset : 8 sectors
   Unused Space : before=1960 sectors, after=1200 sectors
          State : clean
    Device UUID : 97ccd551:8820c0e3:4ab3d67d:908a2fd9

    Update Time : Thu Jul 16 19:02:09 2015
  Bad Block Log : 512 entries available at offset 72 sectors
       Checksum : 9d018eea - correct
         Events : 107223

         Layout : left-symmetric
     Chunk Size : 512K

   Device Role : Active device 2
   Array State : .AA. ('A' == active, '.' == missing, 'R' == replacing)
/dev/sde:
          Magic : a92b4efc
        Version : 1.2
    Feature Map : 0x8
     Array UUID : 839fb405:d0b1f13a:5a55ee42:fc8a2061
           Name : FiFa-Server:0
  Creation Time : Tue Apr 19 08:51:32 2011
     Raid Level : raid5
   Raid Devices : 4

 Avail Dev Size : 3907027120 (1863.02 GiB 2000.40 GB)
     Array Size : 5860538880 (5589.05 GiB 6001.19 GB)
  Used Dev Size : 3907025920 (1863.02 GiB 2000.40 GB)
    Data Offset : 2048 sectors
   Super Offset : 8 sectors
   Unused Space : before=1960 sectors, after=1200 sectors
          State : clean
    Device UUID : 6db7566d:3c709370:12634f66:f6bfd4f6

    Update Time : Thu Jul 16 19:02:09 2015
  Bad Block Log : 512 entries available at offset 72 sectors - bad blocks present.
       Checksum : 4b73aeab - correct
         Events : 107223

         Layout : left-symmetric
     Chunk Size : 512K

   Device Role : spare
   Array State : .AA. ('A' == active, '.' == missing, 'R' == replacing)
/dev/sdf:
          Magic : a92b4efc
        Version : 1.2
    Feature Map : 0x0
     Array UUID : 839fb405:d0b1f13a:5a55ee42:fc8a2061
           Name : FiFa-Server:0
  Creation Time : Tue Apr 19 08:51:32 2011
     Raid Level : raid5
   Raid Devices : 4

 Avail Dev Size : 3907027120 (1863.02 GiB 2000.40 GB)
     Array Size : 5860538880 (5589.05 GiB 6001.19 GB)
  Used Dev Size : 3907025920 (1863.02 GiB 2000.40 GB)
    Data Offset : 2048 sectors
   Super Offset : 8 sectors
   Unused Space : before=1968 sectors, after=1200 sectors
          State : clean
    Device UUID : 27df429f:c9661838:3a8024e4:d55055e8

    Update Time : Thu Jul 16 19:02:09 2015
       Checksum : b4327aa4 - correct
         Events : 107223

         Layout : left-symmetric
     Chunk Size : 512K

   Device Role : Active device 1
   Array State : .AA. ('A' == active, '.' == missing, 'R' == replacing)
/dev/sdg:
          Magic : a92b4efc
        Version : 1.2
    Feature Map : 0x8
     Array UUID : 839fb405:d0b1f13a:5a55ee42:fc8a2061
           Name : FiFa-Server:0
  Creation Time : Tue Apr 19 08:51:32 2011
     Raid Level : raid5
   Raid Devices : 4

 Avail Dev Size : 3907027120 (1863.02 GiB 2000.40 GB)
     Array Size : 5860538880 (5589.05 GiB 6001.19 GB)
  Used Dev Size : 3907025920 (1863.02 GiB 2000.40 GB)
    Data Offset : 2048 sectors
   Super Offset : 8 sectors
   Unused Space : before=1960 sectors, after=1200 sectors
          State : clean
    Device UUID : b6786dff:c6be0236:10d8f95f:63afad93

    Update Time : Thu Jul 16 19:02:03 2015
  Bad Block Log : 512 entries available at offset 72 sectors - bad blocks present.
       Checksum : 397b22c8 - correct
         Events : 107192

         Layout : left-symmetric
     Chunk Size : 512K

   Device Role : Active device 3
   Array State : AAAA ('A' == active, '.' == missing, 'R' == replacing)

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