I recently had a drive fail in a 3 drive RAID 5 array that had been up for nearly 3 years. I've handled this several time before but this time, whilst swapping out the failed drive, a 2nd drive dropped out of the array for some reason and when I tried to add it back, became marked as a spare. I haven't done anything with the new drive yet so whenever I try to start the array, I get one active drive and one spare and hence the array can't start. I can't work out how to prevent the 2nd drive being detected as a spare and allow the array to start with 2 of 3 drives. As far as I can tell from using --examine, the event counts are identical so I'm hoping recovery is feasible. Unfortunately I don't know what order the disks were originally in (all of the original disks have failed and been replaced during the array's life so far). So, 2 questions: Is there a simple way to stop the 2nd drive thinking that it's a spare so I can just assemble the array. If not, I believe I should be able to recreate the array with --assume-clean: How do I determine the correct order for the drives? (If it's a matter of trial and error, how do I know when I get it right?) The output from --examine on the two drives is: /dev/sdb2: Magic : a92b4efc Version : 0.90.00 UUID : cd57d356:c19317bf:a7df5645:f34ebdb2 Creation Time : Fri Mar 20 17:53:13 2009 Raid Level : raid5 Used Dev Size : 1454894336 (1387.50 GiB 1489.81 GB) Array Size : 2909788672 (2774.99 GiB 2979.62 GB) Raid Devices : 3 Total Devices : 4 Preferred Minor : 1 Update Time : Thu Oct 29 18:37:53 2015 State : clean Active Devices : 1 Working Devices : 2 Failed Devices : 2 Spare Devices : 1 Checksum : ca5c1582 - correct Events : 3329174 Layout : left-symmetric Chunk Size : 256K Number Major Minor RaidDevice State this 0 8 66 0 active sync 0 0 8 66 0 active sync 1 1 0 0 1 faulty removed 2 2 0 0 2 faulty removed 3 3 8 50 3 spare /dev/sdd2 /dev/sdd2: Magic : a92b4efc Version : 0.90.00 UUID : cd57d356:c19317bf:a7df5645:f34ebdb2 Creation Time : Fri Mar 20 17:53:13 2009 Raid Level : raid5 Used Dev Size : 1454894336 (1387.50 GiB 1489.81 GB) Array Size : 2909788672 (2774.99 GiB 2979.62 GB) Raid Devices : 3 Total Devices : 4 Preferred Minor : 1 Update Time : Thu Oct 29 18:37:53 2015 State : clean Active Devices : 1 Working Devices : 2 Failed Devices : 2 Spare Devices : 1 Checksum : ca5c1572 - correct Events : 3329174 Layout : left-symmetric Chunk Size : 256K Number Major Minor RaidDevice State this 3 8 50 3 spare /dev/sdd2 0 0 8 66 0 active sync 1 1 0 0 1 faulty removed 2 2 0 0 2 faulty removed 3 3 8 50 3 spare /dev/sdd2 -- 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