I can think of two things I'd do slightly differently...

Do a smartctl -t long on each disk before you do anything, to verify
that you don't have single sector errors on other drives

Use ddrescue for better results copying a failing drive

-Mike

PFC wrote:
> 
>>> I have a raid5 array that contain 4 disk and 1 spare disk. now i saw one
>>> disk have sign of going fail via smart log.
> 
> 
>     Better safe than sorry... replace the failing disk and resync,
> that's all.
> 
>     You might want to do "cat /dev/md# > /dev/null", or "cat /dev/hd? 
> 
>> /dev/null" first. This is to be sure there isn't some yet-unseen bad  
> 
> sector on some other drive which would screw your resync.
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