Array degraded but all drive modules are OK

Hi !
The Xserve RAID is a 14 x 250 Gb P-ATA model. One of the module went bad 3 months ago; I had no spare and the applecare replacement took a whole month to arrive. In the mean time, I bought an Apple 400 Gb P-ATA module and used it without any problem (had to upgrade to 1.5).
Once I received the replacement 250 Go and since I had to reformat the array anyway (purpose of the RAID changed), I swapped the 400 for the 250 and kept the former as a spare.
Sorry for the looong intro, but now, the problem :
Another drive went bust and had to be replaced. Swapped the bad 250 for the "spare" 400 module. A yellow light appeared on the module instead of the green one. No rebuilding was done.
RAID admin says that the array is degraded but if I look at the drives, they are all OK. The only "problem" is that the Drive Cache is disabled for this module and enabled for the others in the array. I tried to re-enable it through the settings but if I restart the array, It switches back to disabled.
I tried to force a parity rebuild. Took almost 5 seconds and did not work. the event log states :
Timestamp: 06/03/06 06:58:42 PM
Priority: Error
Controller: Lower Controller
Type: 47
Event ID: 799
Event: RAID Set 1 Rebuild Complete (-200001)
Description: The RAID set finished rebuilding.
Last thing I tried was to shut down, unplug, wait, replug, restart. done nothing.
I would like to reformat the drive module but I have no P-ATA xserve here. I thought It might have come from the fact It was used before in the same array.
Any ideas ?
Thx.
Eric.

Me again. I backup up the data and deleted the array. When I try to create a new one, the drive module in question is unselectable and a message states :
Drive 12 already belongs to a RAID set. (except it doesn't). I more and more wish I had a P-ATA xserve to format the drive in, but I don't. Any idea on how to format directly a drive module in a Xserve RAID?

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