Summary of problem: My RAID mirror (3ware 7000-2) lost a drive, and it was failing to rebuild with a new replacement disk (under 4.10). I was not sure why the rebuild failed, due to a vague "disk error" message.
At this time I dumped the filesystems to a spare drive, but dump reported a read error on /usr. I fsck'd, but this did not eliminate the problem. Great, my degraded RAID's one "good" disk is having trouble!
It was pointed out to me that fsck would not fix bad blocks. I had to try something else to repair the disk. I located a corrupt file by tarring up /usr and waiting for trouble... A forgotten core dump showed a read error. I deleted it, and a subsequent dump of /usr did not report errors. Progress! However, the RAID would still not rebuild.
It turns out that an IDE drive will not remap a bad sector when READ... it must be WRITTEN. So, after I deleted the file that (presumably) sat on the bad sectors I filled up /usr with misc files. Afterwards, I checked the disk SMART error log and sure enough, it showed some new bad sectors had been remapped. (I checked disk 0 on the RAID with smartctl -a -d 3ware,0 /dev/twed0)
I deleted the temporary files and initiated a RAID rebuild in the 3dm web interface. Before the sector repair, it would die after just a couple of minutes, but after the sector repair the rebuild completed successfully.
SMART still reports that the drive is overall healthy... I am not sure how many spare sectors are left but I have a working mirror again so I have bought myself some time.
Thanks again. -=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-=-= [EMAIL PROTECTED] * KF6IYW * http://wrongcrowd.com "I am Matt Staroscik and I approved this message."
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