Indeed, just glad i decided to give it a try.
The preclear finally moved onto the writing to disk stage, and started putting out a different error, this error kept repeating in the syslog until it was over a GB in size, and it was only 7% done, so I had to close it out, didn't want it to crash the server.
Obviously cant post it all, but its basically just this repeating over and over added onto the previous syslog
Nov 6 18:17:39 Tower kernel: Descriptor sense data with sense descriptors (in hex):
Nov 6 18:17:39 Tower kernel: 72 0b 00 00 00 00 00 0c 00 0a 80 00 00 00 00 00
Nov 6 18:17:39 Tower kernel: 05 ef 2f 68
Nov 6 18:17:39 Tower kernel: sd 1:0:0:0: [sda] ASC=0x0 ASCQ=0x0
Nov 6 18:17:39 Tower kernel: sd 1:0:0:0: [sda] CDB: cdb[0]=0x2a: 2a 00 05 ef 2f 68 00 04 00 00
Nov 6 18:17:39 Tower kernel: end_request: I/O error, dev sda, sector 99561320
Nov 6 18:17:39 Tower kernel: ata1: EH complete
Nov 6 18:17:39 Tower kernel: ata1.00: exception Emask 0x0 SAct 0x0 SErr 0x0 action 0x0
Nov 6 18:17:39 Tower kernel: ata1.00: irq_stat 0x40000001
Nov 6 18:17:39 Tower kernel: ata1.00: failed command: WRITE DMA EXT
Nov 6 18:17:39 Tower kernel: ata1.00: cmd 35/00:00:68:33:ef/00:04:05:00:00/e0 tag 0 dma 524288 out
Nov 6 18:17:39 Tower kernel: res 61/04:00:68:33:ef/4d:04:05:00:00/e0 Emask 0x1 (device error)
Nov 6 18:17:39 Tower kernel: ata1.00: status: { DRDY DF ERR }
Nov 6 18:17:39 Tower kernel: ata1.00: error: { ABRT }
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: configured for UDMA/133 (device error ignored)
Nov 6 18:17:39 Tower kernel: ata1: EH complete
Nov 6 18:17:39 Tower kernel: ata1.00: exception Emask 0x0 SAct 0x0 SErr 0x0 action 0x0
Nov 6 18:17:39 Tower kernel: ata1.00: irq_stat 0x40000001
Nov 6 18:17:39 Tower kernel: ata1.00: failed command: WRITE DMA EXT
Nov 6 18:17:39 Tower kernel: ata1.00: cmd 35/00:00:68:33:ef/00:04:05:00:00/e0 tag 0 dma 524288 out
Nov 6 18:17:39 Tower kernel: res 61/04:00:68:33:ef/4d:04:05:00:00/e0 Emask 0x1 (device error)
Nov 6 18:17:39 Tower kernel: ata1.00: status: { DRDY DF ERR }
Nov 6 18:17:39 Tower kernel: ata1.00: error: { ABRT }
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: configured for UDMA/133 (device error ignored)
Nov 6 18:17:39 Tower kernel: ata1: EH complete
Nov 6 18:17:39 Tower kernel: ata1.00: exception Emask 0x0 SAct 0x0 SErr 0x0 action 0x0
Nov 6 18:17:39 Tower kernel: ata1.00: irq_stat 0x40000001
Nov 6 18:17:39 Tower kernel: ata1.00: failed command: WRITE DMA EXT
Nov 6 18:17:39 Tower kernel: ata1.00: cmd 35/00:00:68:33:ef/00:04:05:00:00/e0 tag 0 dma 524288 out
Nov 6 18:17:39 Tower kernel: res 61/04:00:68:33:ef/4d:04:05:00:00/e0 Emask 0x1 (device error)
Nov 6 18:17:39 Tower kernel: ata1.00: status: { DRDY DF ERR }
Nov 6 18:17:39 Tower kernel: ata1.00: error: { ABRT }
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: configured for UDMA/133 (device error ignored)
Nov 6 18:17:39 Tower kernel: ata1: EH complete
Nov 6 18:17:39 Tower kernel: ata1.00: exception Emask 0x0 SAct 0x0 SErr 0x0 action 0x0
Nov 6 18:17:39 Tower kernel: ata1.00: irq_stat 0x40000001
Nov 6 18:17:39 Tower kernel: ata1.00: failed command: WRITE DMA EXT
Nov 6 18:17:39 Tower kernel: ata1.00: cmd 35/00:00:68:33:ef/00:04:05:00:00/e0 tag 0 dma 524288 out
Nov 6 18:17:39 Tower kernel: res 61/04:00:68:33:ef/4d:04:05:00:00/e0 Emask 0x1 (device error)
Nov 6 18:17:39 Tower kernel: ata1.00: status: { DRDY DF ERR }
Nov 6 18:17:39 Tower kernel: ata1.00: error: { ABRT }
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: configured for UDMA/133 (device error ignored)
Nov 6 18:17:39 Tower kernel: ata1: EH complete
Nov 6 18:17:39 Tower kernel: ata1.00: exception Emask 0x0 SAct 0x0 SErr 0x0 action 0x0
Nov 6 18:17:39 Tower kernel: ata1.00: irq_stat 0x40000001
Nov 6 18:17:39 Tower kernel: ata1.00: failed command: WRITE DMA EXT
Nov 6 18:17:39 Tower kernel: ata1.00: cmd 35/00:00:68:33:ef/00:04:05:00:00/e0 tag 0 dma 524288 out
Nov 6 18:17:39 Tower kernel: res 61/04:00:68:33:ef/4d:04:05:00:00/e0 Emask 0x1 (device error)
Nov 6 18:17:39 Tower kernel: ata1.00: status: { DRDY DF ERR }
Nov 6 18:17:39 Tower kernel: ata1.00: error: { ABRT }
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: configured for UDMA/133 (device error ignored)
Nov 6 18:17:39 Tower kernel: ata1: EH complete
Nov 6 18:17:39 Tower kernel: ata1.00: exception Emask 0x0 SAct 0x0 SErr 0x0 action 0x0
Nov 6 18:17:39 Tower kernel: ata1.00: irq_stat 0x40000001
Nov 6 18:17:39 Tower kernel: ata1.00: failed command: WRITE DMA EXT
Nov 6 18:17:39 Tower kernel: ata1.00: cmd 35/00:00:68:33:ef/00:04:05:00:00/e0 tag 0 dma 524288 out
Nov 6 18:17:39 Tower kernel: res 61/04:00:68:33:ef/4d:04:05:00:00/e0 Emask 0x1 (device error)
Nov 6 18:17:39 Tower kernel: ata1.00: status: { DRDY DF ERR }
Nov 6 18:17:39 Tower kernel: ata1.00: error: { ABRT }
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: failed to enable AA(error_mask=0x1)
Nov 6 18:17:39 Tower kernel: ata1.00: configured for UDMA/133 (device error ignored)
Nov 6 18:17:39 Tower kernel: sd 1:0:0:0: [sda] Result: hostbyte=0x00 driverbyte=0x08
Nov 6 18:17:39 Tower kernel: sd 1:0:0:0: [sda] Sense Key : 0xb [current] [descriptor
However, smart test for the drive shows up as fine with no errors, no sectors pending or reallocated. There are a bunch of other fault codes though. It is attached.
smart.txt