RAID 5 not bootable

My Mac Pro running 5.8 with a card running RAID 5 had worked well for 2.5 years.  Recently, it would attempt to boot and stall at the apple screen and shut down.  I booted from CD, and RAID utility said that a rebuild was necessary.  4 drives in the bays.  After rebuild, all green lights.  The system will still not boot from the RAID drive.  I booted in target disk mode and could see the RAID drive and obtain data from it.  There was a warning that the drive was not reliable, or something of the sort.  All data is intact and backed up, though not in time machine.  How do I restore functionality to the RAID Array?  Any tips to test the function of the raid card, or are green lights enough? 

HFS has a little bit of trouble with its own integrity. For one, it doesn't pass along or record I/O errors well, that is one area that SoftRAID has but of course not an option.
SuperDuper is full volume mirror images; bootable backups. I even store a system image on sparse DMG I keep on an array that I can mount and restore, as well as boot volumes.
Disk Warrior is desgined like TechTool Pro 6 to be run ideally from a hard drive, one designated just for that type of use. A minimal but complete set of drivers and utilities running latest OS version.
The idea is if the system (and most errors are with system and not data) goes belly-up, you can just restore a good system image.
A separate OS partition - part of your RAID; another just for system maintenance.
I would never rely on TimeMachine, but at least you have multiple sets. 
Redundancy in backup sets and methods. 
Even if one backup goes the other is intact.
Always having one set off line at any given time.
If you have over 3TB of data, then you must have a large drive or even 2nd RAID0 to accomodate (TimeMachine likes to have capacity 3.5x the data).

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