[SOLVED] Possibly dead hard drive or bad raid setup...

I have a 4 drive raid5 running. Just recently one of the drives kept removing itself from the array. I have re / formated / partitioned the drive multiple times, but either mdadm doesn't accept the drive, or it accepts, resyncs, and when i try to access the raid it fails again.
I eventually pulled the drive out and plugged it into my desktop machine. That machine recognized the partition fine. However after putting the drive back into the raid i receive these sort of errors on startup:
Jun 8 17:04:41 localhost kernel: [ 213.942913] ata3.00: failed command: READ DMA
Jun 8 17:04:41 localhost kernel: [ 213.942922] ata3.00: cmd c8/00:08:40:10:00/00:00:00:00:00/e0 tag 0 dma 4096 in
Jun 8 17:04:41 localhost kernel: [ 213.942924] res 51/40:00:40:10:00/00:00:00:00:00/e0 Emask 0x9 (media error)
Jun 8 17:04:41 localhost kernel: [ 213.942928] ata3.00: status: { DRDY ERR }
Jun 8 17:04:41 localhost kernel: [ 213.942931] ata3.00: error: { UNC }
Jun 8 17:04:41 localhost kernel: [ 213.979780] ata3.00: configured for UDMA/133
Jun 8 17:04:41 localhost kernel: [ 213.979794] ata3: EH complete
Jun 8 17:04:44 localhost kernel: [ 216.508311] ata3.00: exception Emask 0x0 SAct 0x0 SErr 0x0 action 0x0
Jun 8 17:04:44 localhost kernel: [ 216.508316] ata3.00: BMDMA stat 0x24
Jun 8 17:04:44 localhost kernel: [ 216.508321] ata3.00: failed command: READ DMA
Jun 8 17:04:44 localhost kernel: [ 216.508330] ata3.00: cmd c8/00:08:40:10:00/00:00:00:00:00/e0 tag 0 dma 4096 in
Jun 8 17:04:44 localhost kernel: [ 216.508332] res 51/40:00:40:10:00/00:00:00:00:00/e0 Emask 0x9 (media error)
Jun 8 17:04:44 localhost kernel: [ 216.508336] ata3.00: status: { DRDY ERR }
Jun 8 17:04:44 localhost kernel: [ 216.508339] ata3.00: error: { UNC }
Jun 8 17:04:44 localhost kernel: [ 216.538146] ata3.00: configured for UDMA/133
Jun 8 17:04:44 localhost kernel: [ 216.538160] ata3: EH complete
Jun 8 17:04:47 localhost kernel: [ 219.073696] ata3.00: exception Emask 0x0 SAct 0x0 SErr 0x0 action 0x0
Jun 8 17:04:47 localhost kernel: [ 219.073701] ata3.00: BMDMA stat 0x24
Jun 8 17:04:47 localhost kernel: [ 219.073705] ata3.00: failed command: READ DMA
Jun 8 17:04:47 localhost kernel: [ 219.073714] ata3.00: cmd c8/00:08:40:10:00/00:00:00:00:00/e0 tag 0 dma 4096 in
Jun 8 17:04:47 localhost kernel: [ 219.073716] res 51/40:00:40:10:00/00:00:00:00:00/e0 Emask 0x9 (media error)
Jun 8 17:04:47 localhost kernel: [ 219.073720] ata3.00: status: { DRDY ERR }
Jun 8 17:04:47 localhost kernel: [ 219.073723] ata3.00: error: { UNC }
Jun 8 17:04:52 localhost kernel: [ 224.093967] ata3.00: qc timeout (cmd 0x27)
Jun 8 17:04:52 localhost kernel: [ 224.093972] ata3.00: failed to read native max address (err_mask=0x4)
Jun 8 17:04:52 localhost kernel: [ 224.093976] ata3.00: HPA support seems broken, skipping HPA handling
Jun 8 17:04:52 localhost kernel: [ 224.093980] ata3.00: revalidation failed (errno=-5)
Jun 8 17:04:52 localhost kernel: [ 224.093989] ata3: hard resetting link
Jun 8 17:04:52 localhost kernel: [ 224.567030] ata3: SATA link up 3.0 Gbps (SStatus 123 SControl 300)
Jun 8 17:04:52 localhost kernel: [ 224.587154] ata3.00: configured for UDMA/133
Jun 8 17:04:52 localhost kernel: [ 224.587174] sd 2:0:0:0: [sde] Unhandled sense code
Jun 8 17:04:52 localhost kernel: [ 224.587177] sd 2:0:0:0: [sde] Result: hostbyte=0x00 driverbyte=0x08
Jun 8 17:04:52 localhost kernel: [ 224.587182] sd 2:0:0:0: [sde] Sense Key : 0x3 [current] [descriptor]
Jun 8 17:04:52 localhost kernel: [ 224.587187] Descriptor sense data with sense descriptors (in hex):
Jun 8 17:04:52 localhost kernel: [ 224.587190] 72 03 11 04 00 00 00 0c 00 0a 80 00 00 00 00 00
Jun 8 17:04:52 localhost kernel: [ 224.587202] 00 00 10 40
Jun 8 17:04:52 localhost kernel: [ 224.587207] sd 2:0:0:0: [sde] ASC=0x11 ASCQ=0x4
Jun 8 17:04:52 localhost kernel: [ 224.587212] sd 2:0:0:0: [sde] CDB: cdb[0]=0x28: 28 00 00 00 10 40 00 00 08 00
Jun 8 17:04:52 localhost kernel: [ 224.587223] end_request: I/O error, dev sde, sector 4160
Jun 8 17:04:52 localhost kernel: [ 224.587228] Buffer I/O error on device sde1, logical block 512
I have tried using SMART to test the drives, however all the drives seem to fail with some sort of error. I believe this is a false positive as I have read elsewhere that the 1TB Green Western Digitals (WD10EARS) seem to have problems with SMART.
Is this drive dead? Its only a year old... and unfortunately just out of warranty.
Last edited by passbe (2011-06-24 08:52:16)

Ok so i zero filled /dev/sde, and re-added it back to the array. It synced (for 2 days), and then my RAID5 completely failed. I can't bring it back up at all now. My BIOS says one of the hard drives is dead (SMART error). Fair enough drive is dead. But now i cant get the 3 drives back up and running in the RAID.
I have attempted the following:
sudo mdadm --assemble -vv /dev/md127 /dev/sdb1 /dev/sdc1 /dev/sdd1
mdadm: looking for devices for /dev/md127
mdadm: cannot open device /dev/sdb1: Device or resource busy
mdadm: /dev/sdb1 has no superblock - assembly aborted
It complains that every device does not have a superblock?
A mdadm --examine on each drive:
/dev/sdb1
Magic : a92b4efc
Version : 1.2
Feature Map : 0x0
Array UUID : e3da6078:d4699e2d:c1da42cc:d58a42bf
Name : myhost:0
Creation Time : Sun Feb 27 09:27:39 2011
Raid Level : raid5
Raid Devices : 4
Avail Dev Size : 1953517954 (931.51 GiB 1000.20 GB)
Array Size : 5860552704 (2794.53 GiB 3000.60 GB)
Used Dev Size : 1953517568 (931.51 GiB 1000.20 GB)
Data Offset : 2048 sectors
Super Offset : 8 sectors
State : clean
Device UUID : 95618add:2d0b86be:d06cc198:1a5e101f
Update Time : Tue Jun 14 20:44:51 2011
Checksum : 51b4a80f - correct
Events : 4808
Layout : left-symmetric
Chunk Size : 512K
Device Role : Active device 0
Array State : A.A. ('A' == active, '.' == missing)
/dev/sdc1
Magic : a92b4efc
Version : 1.2
Feature Map : 0x0
Array UUID : e3da6078:d4699e2d:c1da42cc:d58a42bf
Name : myhost:0
Creation Time : Sun Feb 27 09:27:39 2011
Raid Level : raid5
Raid Devices : 4
Avail Dev Size : 1953517954 (931.51 GiB 1000.20 GB)
Array Size : 5860552704 (2794.53 GiB 3000.60 GB)
Used Dev Size : 1953517568 (931.51 GiB 1000.20 GB)
Data Offset : 2048 sectors
Super Offset : 8 sectors
State : clean
Device UUID : 3056502e:51e004d0:4380f027:fe2d9ebc
Update Time : Tue Jun 14 20:44:51 2011
Checksum : e0b65526 - correct
Events : 4808
Layout : left-symmetric
Chunk Size : 512K
Device Role : Active device 2
Array State : A.A. ('A' == active, '.' == missing)
/dev/sdd1
Magic : a92b4efc
Version : 1.2
Feature Map : 0x0
Array UUID : e3da6078:d4699e2d:c1da42cc:d58a42bf
Name : myhost:0
Creation Time : Sun Feb 27 09:27:39 2011
Raid Level : raid5
Raid Devices : 4
Avail Dev Size : 1953517954 (931.51 GiB 1000.20 GB)
Array Size : 5860552704 (2794.53 GiB 3000.60 GB)
Used Dev Size : 1953517568 (931.51 GiB 1000.20 GB)
Data Offset : 2048 sectors
Super Offset : 8 sectors
State : clean
Device UUID : 3b7ea2c8:9fd80575:94fbe3a0:cde69026
Update Time : Tue Jun 14 20:34:16 2011
Checksum : 2f1a716 - correct
Events : 4791
Layout : left-symmetric
Chunk Size : 512K
Device Role : Active device 1
Array State : AAAA ('A' == active, '.' == missing)
/dev/sde1 (This is the bad drive)
Magic : a92b4efc
Version : 1.2
Feature Map : 0x0
Array UUID : e3da6078:d4699e2d:c1da42cc:d58a42bf
Name : myhost:0
Creation Time : Sun Feb 27 09:27:39 2011
Raid Level : raid5
Raid Devices : 4
Avail Dev Size : 1953523057 (931.51 GiB 1000.20 GB)
Array Size : 5860552704 (2794.53 GiB 3000.60 GB)
Used Dev Size : 1953517568 (931.51 GiB 1000.20 GB)
Data Offset : 2048 sectors
Super Offset : 8 sectors
State : clean
Device UUID : bad3c5fd:3e439065:957ca15a:412339dc
Update Time : Tue Jun 14 20:44:51 2011
Checksum : 98033b24 - correct
Events : 4808
Layout : left-symmetric
Chunk Size : 512K
Device Role : spare
Array State : A.A. ('A' == active, '.' == missing)
The only difference being that /dev/sdd1 thinks that the RAID has all four devices? Where do i go from here, I'm completely stuck and about to loose 50% of my data. Help!?!

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[SOLVED] Possibly dead hard drive or bad raid setup...

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