RAID drives down-contoller won't start up

Running FCP5 on a G5 (dual 2, OS 10.4.7), XServe RAID with 14X250G drives, running RAID 5. Here's the situation: I had drive 11 start to flake out on me yesterday. After rebooting the XServe, the RAID came up and automatically started to rebuild the array. Left it overnight and came back the next mowning to find everything seemed to say it was OK.
After about an hour, this same drive red lighted. I've had one other drive fail before, so I popped it out to keep running (since running RAID 5). Then, as I'm editing for the next hour or two everything seemed fine. Then drive 8 began to act a little strange.... during playback of a timeline, FCP would freeze playback and the drive 8 blue light would come on solid, almost like it couldn't keep up with the throughput.
After another episode of that, suddenly, the drive seemd to red light briefly. I lost connection with that array and all the video connection disappeared from the timeline (media missing). I rebooted everything, now the array in question was not accessible from the RAID admin. I could see the drives, they said they were green, but no array existed on that side. Array 1 was all still there, but the "video" drive would not mount. I then tried various combinations of rebooting and then firmware updates. Nothing made any changes until this morning when re-attempting, suddenly the RAID controller for that same array will now not start. In the admin it shows a warning in the component view.
Really trying to figure out the next step here since I'm dead in the water.... Any ideas on trouble shooting? How to at least get the controller back up? Could it be bad and have caused the drives to have problems?
David
MacBook Mac OS X (10.4.7) 1G RAM, 2Ghz Core Duo

Hi David,
So you removed drive 11 and then replaced it with the same drive, and then rebuilt?
Also, if in fact the drive did fail, and you removed it and continued to edit with the drive missing, and in fact had a failure on drive 8, then it's "game over." 2 failures on one array loses the array with RAID 5. I can't say this is what happened -- but if it's the case it's trouble. You also didn't say what firmware version you were running at the time of the failure (that's important -- more than the version you upgraded to post update). The 1.5 firmware has an option to "recognize array" which can get arrays back in some very specific circumstances, but you have to be running 1.5 when the issue occurs... not update to it after the fact.
The thing is, both RAID controllers should be able to see and manage both sides of the array. When you connect to the upper controller, what do you see in the event log?
This might be a good time to call AppleCare.

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