Summary: Thanks for your quick feedback! You can close this as invalid. I do understand BTS is not general support forum, and I was genuinely believing that there was bug in mdadm, as I though both source and destination disks were without errors (despite SMART errors I've got on /dev/sde, it looked undamaged and it's removal was supposed to be preemptive). That belief was reinforced by seeing /proc/mdstat showing sync progress going above 99.9% without aborting.
The steps I've tried that look like usage errors (-G -n2, ...) were my last-resort (perhaps misguided) attempts to force mdadm to realize there are supposed to be two ACTIVE disks in the array (aand not active+spare) - and I've only tried them the because regular way (mdadm --add, --remove) didn't work when I though it really should. That being said, you were correct afterall :-) Your response prompted me to doublecheck, and I've run badblocks(8) on both destination disks (both ok) and source /dev/sde2 disk. And the source disk was really having bad sectors - about 80 of them, at 99.97%. That last 0.03% was visually too quick to notice, so I was fooled by /proc/mdstat showing how it progresses from 0% to 99.9%+ without error and I wrongly assumed it did manage to finish the sync (but somehow didn't update the active/spares, due to some bug) Some hammering with hdparm --write-sector managed to zero-out that few sectors (which didn't appear to be used by any files), and after that mdadm did finish the sync. Anyway, may the bug be archived for future adventurers with same problem. -- Opinions above are GNU-copylefted. -- To UNSUBSCRIBE, email to debian-bugs-dist-requ...@lists.debian.org with a subject of "unsubscribe". Trouble? Contact listmas...@lists.debian.org