I've also run into this.  And there seems to be a fair number on the
Ubuntu forums that have experienced it also.

This bug can cause Ubuntu 8.04to hang (become completely unresponsive),
presumably due to the logs getting filed with 'md: array md0 already has
disks!' many times per second.  Also, this error start appearing in the
kernel log just after you the kernel states it has loaded symbols and it
starts in mid error.  So, you really don't know what is happening that
leads up to this.

I've tried every work around that I can find that has been suggested in
the forums, e.g. reinstalling mdadm, rebuilding the array from scratch,
etc.  But none have worked.

The only work around is to at the earliest opportunity, either in a busy
box, if presented with one, or immediately after you log in you do the
following:

  1) sudo mdadm -S /dev/md0  ( mdadm -S /dev/md0, if in a busy box)
  2) then check the log with dmesg | tail ( dmesg | /usr/bin/tail, if you are 
in a busybox) 
  3) if the error 'md: array md0 already has disks!' has not stopped, repeat 
steps 1 & 2 until it does.
       - I'm finding more and more that it takes repeating the steps 3-4 times 
before things settle down.
  4) once the error stops, if the array is listed in the /etc/fstab, you can 
issue a sudo mount /dev/md0 (mount /dev/md0, if in a busy box) and things will 
then work until the next reboot.

-- 
mdam software raid fails to start up on reboot
https://bugs.launchpad.net/bugs/188392
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