Are you sure the replacement disk has the same physical sector size? It's not 
like vendors don't change specs on newer versions of the same model sometimes 
:(. What exactly is it? Is it by any chance one of those 4K drives with a 
jumper that controls whether or not it lies about the physical sector size?

> On Nov 20, 2015, at 8:44 PM, Doug Hughes <d...@will.to> wrote:
> 
> When this pool was setup, it was with a different controller that didn't 
> support > 2TB / disk. When the controller was replaced, the pool is still set 
> for ashift=9, but if I try to replace a disk in it with another disk of 
> exactly the same model I get the annoying error:
> 
> root@x4275-3-15-22:/root# zpool replace zpool1 c0t5000CCA22BC8F4C2d0 
> c0t5000CCA3DE1719Fd0
> cannot replace c0t5000CCA22BC8F4C2d0 with c0t5000CCA23DE1719Fd0: devices have 
> different sector alignment
> 
> I know there's a -o ashift=9 option for Linux. Is there some sort of 
> equivalent action that I can take, perhaps upgrading the existing zpool 
> without having to recreate it?
> 
> Thanks
> 
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