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[SOLVED] Failing drive in middle of rebuild. Need to re-install old smaller d...

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j.metts:
I recently returned from vacation to find that I had left my A/C off and one of my hard drives had overheated and was taken offline. I have had an issue with cooling on a couple of my drives, so this didn't surprise me. After looking into things and verifying it had overheated, I ran a SMART report and everything checked out fine. I removed the drive from the array and reassigned it again, and to be safe, had the drive get rebuilt. I then took care of my cooling problem once and for all. All of this went fine.

A couple days later, and while everything had been running just fine, I decided to go ahead and pre-clear a newish 2TB drive I've had in the machine for about 6 months now, but had never taken the time to pre-clear it and have it replace a smaller drive in my system. The drive pre-cleared fine, and I went to replace a smaller 500GB drive in my system last night. As soon as I went to have the new 2TB drive rebuilt with the 500GB drive's data, the drive that had overheated earlier started throwing out a ton of "handle_stripe read error" lines in the syslog. I reran a SMART report on the drive, and sure enough, it appears to be failing.

Now, the original 500GB drive is still in the machine and I want to just reinstate it where it was and use the 2TB drive that I was having the 500GBs contents rebuilt to as the replacement drive for the failing one. I canceled the rebuild process and went to reassign the old drive back in it's place, but this is where I should have done some research beforehand not thinking that this would be trying to replace a 2TB drive with a 500GB drive. Sure enough, it doesn't want to replace the drive with a smaller drive. I know the data on the 500GB drive is fine, but when I replaced the 500GB with the 2TB, did this immediately change my parity drive so that I won't be able to go back? And if I can, will parity still be good to rebuild the failing 2TB drive on my replacement drive?

Thanks for the help!

Joe L.:
As long as you have a copy of the config directory from before you swapped in the new/larger drive, no problem.

Copy back the old config folder, put the disks back as they were, and you will be back to where you were prior to the upgrade.

j.metts:

--- Quote from: Joe L. on August 20, 2012, 07:48:05 AM ---As long as you have a copy of the config directory from before you swapped in the new/larger drive, no problem.

Copy back the old config folder, put the disks back as they were, and you will be back to where you were prior to the upgrade.

--- End quote ---

Sadly, I didn't make a copy of the config directory. This was the first time I have upgraded a drive, and I just followed the instructions in the FAQ / Manual:

http://lime-technology.com/wiki/index.php/UnRAID_Manual#Replace_a_single_disk_with_a_bigger_one

It didn't mention making a copy of the config directory, and I didn't think to do it.

Are there any other solutions?

j.metts:
Maybe I should add that the drive that is failing still shows a green ball in the unRAID WebGUI, not a red ball. I should have made that clear. The drive is failing, but unRAID isn't yet reporting a failed drive in this case.

j.metts:
So, I've been researching all day as to what I experienced last night, and still don't have a solution just yet. When I get home, I'll power up the machine, run a SMART report on the 2TB "failing" drive to post here (along with a syslog showing the errors), but the report last night showed it was failing due to "Reallocated Sectors Count" being 1260....which is a lot! And I'm assuming this is the cause of the "handle_stripe read" errors in the syslog. I figured the overheating must have caused this??? Although the rebuild on this overheated drive was slow, it completed and the system was in usable condition for a couple days before I decided to replace the small 500GB drive with my spare 2TB drive. That is when I saw all of the "handle_stripe read" errors. From what I have read, unRAID will only pull a drive offline if it can't write to the drive. I have also read that most large drives these days have thousands of reserved sectors for remap, and although 1260 is huge, and I feel the drive definitely needs to be replaced, I'm curious if I should just let the rebuild do its thing on the replaced 500GB drive.

I would really like to get the 500GB back in its place, but since I don't have a saved config, I have yet to find how to do this without invalidating parity.

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