I have just recently encountered this error on two new HDDs that I am trying to replace an old one with. I have replaced 8-10 HDDs over the last 3-4 years, all have been precleared with no errors. And both will finish the data rebuild, but the same error will remain. I swap out the old HDD with the new one/ones after I stop the array and remove the disk from the array, and then power off the server. Turn on the server, select the pre-cleared drive in the empty drive, and as soon as I start the array, after it formats, it gives me the unmountable disk error. Ay help would be appreciated, I have tried it a few different ways and just can't get it to work.