Faceman

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  1. Faceman
    Faceman's post in Cannot replace drive in array. was marked as the answer   
    without a parity disk you cant do the standard disk swap procedure as there is no way to rebuild the data onto the new disk.
     
    Definitely need to go the New Config route to get it to forget that 40gb disk ever existed and not have to replace it with a new disk.
     
    Alternatively, add a parity disk now, let it rebuild, then you will be able to replace the 40gb with a proper disk after that.