I have a brand new 3TB Hitachi 5K3000 that just finished 3 preclear cycles with 58 reallocated sectors (and 70 reallocated events?). Final SMART output is attached. Preclear actually said that there were 0 sectors pending reallocation after the 1st 2 passes, but if you look at the individual "smart_mid_post_read1" log, it really shows up after the first pass (bug in preclear?). This is confirmed by these entries in the syslog during the first pass, with no similar entries in later passes:
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 17 dc 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907533312
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441664
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441665
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441666
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441667
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441668
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441669
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441670
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441671
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441672
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: Buffer I/O error on device sdc, logical block 113441673
Sep 5 10:24:20 tower kernel: lost page write due to I/O error on sdc
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 17 e0 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907534336
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 17 e4 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907535360
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 17 e8 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907536384
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 17 ec 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907537408
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 17 f0 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907538432
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 17 f4 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907539456
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 17 f8 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907540480
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 17 fc 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907541504
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 18 00 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907542528
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 18 04 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907543552
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 18 08 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907544576
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 18 28 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907552768
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 18 2c 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907553792
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Unhandled error code
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] Result: hostbyte=0x00 driverbyte=0x06
Sep 5 10:24:20 tower kernel: sd 3:0:0:0: [sdc] CDB: cdb[0]=0x2a: 2a 00 36 18 30 00 00 04 00 00
Sep 5 10:24:20 tower kernel: end_request: I/O error, dev sdc, sector 907554816
The sector count reallocation was stable through the 2nd two runs, but I'm still inclined to send back a brand new drive with any problems. Unfortunately, Newegg doesn't have any more of these in stock, so an exchange through them may not be an option. I'd hate to RMA a brand new drive and get a refurbished one back. Am I being too paranoid?
preclear_MJ1311YNG7RNDA_2012-09-09.zip