If you do have to replace the drive - you will need to add the new 
drive, then partition the new drive to match the old drive partition 
size layout, make them as type "fd" and then do the -add command for 
each partition you are re-adding into your mirror sets using mdadm.

Good luck!

On 04/02/2012 11:44 AM, Wayne Johnson wrote:
> It's been a while since I did this. A search on google gives
> http://www.tcpdump.com/kb/os/linux/removing-failed-raid-devices.html
> which seems right.
>
> The commands (you will have to adjust it for your configuration) would be:
>
> mdadm /dev/md0 --fail /dev/sdc1
> This will fail the suspect drive (if not already).
>
> mdadm /dev/md0 --remove /dev/sdc1
> This will remove the drive from the array.
>
> mdadm /dev/md0 --add /dev/sdc1
> This adds the drive back into the array. It will then resync the failed
> drive. You can see this by doing cat /proc/mdstat:
>
> # cat /proc/mdstat
> Personalities : [raid6] [raid5] [raid4]
> md0 : active raid5 sdc1[1] sdb1[0] sdd1[2]
> 8385664 blocks level 5, 64k chunk, algorithm 2 [3/2] [U_U]
> [=========>...........] recovery = 47.8% (2007428/4192832) finish=0.5min
> speed=62732K/sec
>
> unused devices:
>
>
>
> ---
> Wayne Johnson, | There are two kinds of people: Those
> 3943 Penn Ave. N. | who say to God, "Thy will be done,"
> Minneapolis, MN 55412-1908 | and those to whom God says, "All right,
> (612) 522-7003 | then, have it your way." --C.S. Lewis
>
>     ------------------------------------------------------------------------
>     *From:* Mike Miller <mbmiller+l at gmail.com>
>     *To:* Wayne Johnson <wdtj at yahoo.com>; TCLUG Mailing List
>     <tclug-list at mn-linux.org>
>     *Sent:* Monday, April 2, 2012 10:38 AM
>     *Subject:* Re: [tclug-list] fixing a RAID1 after drive failure
>
>     On Mon, 2 Apr 2012, Wayne Johnson wrote:
>
>      > On Mon, 2 Apr 2012, Mike Miller wrote:
>      >
>      >> Suppose one drive failed in my RAID1 mirrored pair. Can I then
>     simply pull the bad drive, replace it with a good one (brand new),
>     and have it work? Will it just automagically rebuild the RAID1 by
>     mirroring onto the new drive?
>      >>
>      >> This is Ubuntu software RAID1.
>      >
>      > Actually, in my experience, the drive may not have a permement
>     failue. You can re-activate the drive again, it will resync the
>     failed drive, and you are running again. If it happens too
>     frequently, replace the drive.
>
>     How do I reactivate a drive? That sounds like a great idea.
>
>     Mike
>
>
>
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