RAID won't unmount...can't repair

Problem: after fixed failed RAID (lost in poweroutage), RAID'd drive won't mount. If I drop to single user mode and fsck the boot volume (no errors listed), after reboot it's the RAID volume is back. I loose it after a restart without fsck (boot volume loads but RAID is "unrecognizeable").
When it mounts everything functions as it should (users get home folders and have read/wrote access, etc.). However if I try to repair it in disk utility (per Apple phone support), i get an error message saying that the disk can't unmount so therefore can't check it.
Any suggestions (besides clean install) that you have to keep the RAID volume intact? I refuse to believe that it's toast as i am able to have it function. I guess I wouldn't be opposed to a wipe if I could get a good backup of it, but I can't even do that since it won't unmount.
Can't wait to hear what you come up with!
Thanks in advance.

Really, how toasted can it be when it all works flawlessly
until reboot? THis really bothers me....
Don't get me started about the Apple Hardware RAID card. I hope you have the write caches turned off for all LUNs because they don't always fully flush on graceful power down (the drives are disconnected from the bus before caches are flushed) - I've had a RADAR bug report turned in for almost 2 years on that, it was very hard to track down and create a reproducible test case. LSI Logic fixed the bug in their microcode after Apple split its version from the LSI Logic code tree to modify for use in the Xserve; don't expect this bug to ever be fixed because the product is EOL, only known workaround is to turn off the write caches.
That said, the disks are big. You think it's working flawlessly, but it may not be. Mystery garbage blocks from space, especially on a RAID, can be hard to track down. For example, on a RAID 1, the read data might not always come from the same disk of the mirror.
If you really think that the mirror is good, I'd suggest cloning it off while booted from another disk (perhaps split the mirror, clone - not image - to one of the split disks, then recreate the mirror from the good copy).
Yea, your DiskWarrior issue is because the disk can't be unmounted.
Russ
Xserve G5 2.0 GHz 2 GB RAM   Mac OS X (10.4.8)   Apple Hardware RAID, ATTO UL4D, Exabyte VXA-2 1x10 1u

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