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Both drives that produced the error were new WD internal drives installed in the Unraid array straight out of the box.

Hi Johnathan. I did't have a spare system to use as a testbed, so I swapped the drive in question into the cache drive slot and vice versa. In this configuration, I was able to run hdparm -N on the cache drive (now in the bad drive slot), but received the same error on the questionable drive (now in the cache drive slot). That indicated it was the drive. Got a new Seagate drive and that's rebuilding fine now. My concern is that 2 brand new WD 4TB drives failed in a row - not returning HPA data when queried. Is that just bad luck, or could there be REVs of WD drives incompatible with Unraid? Again, thanks for the help.

Thank you again for your help. I don't think it's the controller. I was able to run hdparm -N on all of the other drives in the array without error. Also, this drive, as well as the previous drive I received the "drive too small" error on, were both new out of the box. Any other thoughts or suggestions would be greatly appreciated.

Thank you for the suggestion. Running hdparm -N gets this result: "READ_NATIVE_MAX_ADDRESS_EXT failed: Input/output error." I was able to run hdparm -I and hdparm -tT successfully on the same drive. Not sure what to make of this. root@Tower:~# hdparm -I /dev/sdd /dev/sdd: ATA device, with non-removable media Model Number: WDC WD40EZRX-00SPEB0 Serial Number: WD-WCC4E0614977 Firmware Revision: 80.00A80 Transport: Serial, SATA 1.0a, SATA II Extensions, SATA Rev 2.5, SATA Rev 2.6, SATA Rev 3.0 Standards: Supported: 9 8 7 6 5 Likely used: 9 Configuration: Logical max current cylinders 16383 16383 heads 16 16 sectors/track 63 63 -- CHS current addressable sectors: 16514064 LBA user addressable sectors: 268435455 LBA48 user addressable sectors: 7813971633 Logical Sector size: 512 bytes Physical Sector size: 4096 bytes device size with M = 1024*1024: 3815415 MBytes device size with M = 1000*1000: 4000753 MBytes (4000 GB) cache/buffer size = unknown Nominal Media Rotation Rate: 5400 Capabilities: LBA, IORDY(can be disabled) Queue depth: 32 Standby timer values: spec'd by Standard, with device specific minimum R/W multiple sector transfer: Max = 16 Current = 16 DMA: mdma0 mdma1 mdma2 udma0 udma1 udma2 udma3 udma4 udma5 *udma6 Cycle time: min=120ns recommended=120ns PIO: pio0 pio1 pio2 pio3 pio4 Cycle time: no flow control=120ns IORDY flow control=120ns Commands/features: Enabled Supported: * SMART feature set Security Mode feature set * Power Management feature set * Write cache * Look-ahead * WRITE_BUFFER command * READ_BUFFER command * NOP cmd * DOWNLOAD_MICROCODE Power-Up In Standby feature set * SET_FEATURES required to spinup after power up * 48-bit Address feature set * Device Configuration Overlay feature set * Mandatory FLUSH_CACHE * FLUSH_CACHE_EXT * SMART error logging * SMART self-test * General Purpose Logging feature set * 64-bit World wide name * WRITE_UNCORRECTABLE_EXT command * {READ,WRITE}_DMA_EXT_GPL commands * Segmented DOWNLOAD_MICROCODE * Gen1 signaling speed (1.5Gb/s) * Gen2 signaling speed (3.0Gb/s) * Gen3 signaling speed (6.0Gb/s) * Native Command Queueing (NCQ) * Host-initiated interface power management * Phy event counters * NCQ priority information * unknown 76[15] DMA Setup Auto-Activate optimization Device-initiated interface power management * Software settings preservation * SMART Command Transport (SCT) feature set * SCT Write Same (AC2) * SCT Features Control (AC4) * SCT Data Tables (AC5) unknown 206[12] (vendor specific) unknown 206[13] (vendor specific) unknown 206[14] (vendor specific) * reserved 69[4] Security: Master password revision code = 65534 supported not enabled not locked frozen not expired: security count supported: enhanced erase more than 508min for SECURITY ERASE UNIT. 2min for ENHANCED SECURITY ERASE UNIT. Logical Unit WWN Device Identifier: 50014ee2b4351d95 NAA : 5 IEEE OUI : 0014ee Unique ID : 2b4351d95 Checksum: correct root@Tower:~# hdparm -tT /dev/sdd /dev/sdd: Timing cached reads: 2278 MB in 2.00 seconds = 1139.78 MB/sec Timing buffered disk reads: 426 MB in 3.01 seconds = 141.53 MB/sec

Thanks for the reply. I saw this potential cause mentioned in other posts involving the "replacement disk too small" error, however I don't believe this is my problem there's no indication HPA was detected in my log and my motherboard is a SuperMicro.

Hi all, This morning I had a red-balled disk in my array. Stopped the array, powered down, and replaced the drive with a new one of the same size and make. Restarted and, upon assigning the new drive, received the error "Replacement disk is too small." Both the new and old disk are listed as 4TB on the device status page. Figuring there might be a problem with the new drive, I tried another new drive with the same results. unRAID Server Pro version: 5.0.4. System log attached. Any help would be greatly appreciated. Thanks! systemLog.txt