System crashed and now encryption password won't work

tl;dr

System had a major crash.  Now the encryption password for one of the disks won't work. I am 100% certain I am using the correct passphrase. What can I do?

Full story

Yesterday my system seemed to be working fine (Unraid v6.9).  Came back after a few hours and it was very unresponsive.  Log in and see there are a ton of errors and some of the disks aren't reading properly.  I manage to restart it but once I do,  3 of the drives are no longer visible. They are just missing from the array.  I'm not sure exactly what happened (some of the drives are routed through a sata expansion card (https://www.amazon.com/dp/B01464550K?tag=pcpapi-20&linkCode=ogi&th=1&psc=1) so maybe that crashed. Maybe one of the drives was on its way out and took everything down with it, I don't really know). Anyways, concerned about the disks I take the drives out and connect them to my Ubuntu laptop to make sure data is ok.  Can mount them no problem on the laptop and all the drives seem ok. One drive in the array is encrypted and when I used the passphrase with the laptop it worked no problem.  All the data seemed safe.  I move the sata card to another pci slot and put everything back into the machine and start it up and it can now see the missing drives. Ok great. Type in the password. WRONG PASSPHRASE. Hmmmm that's odd, this worked 10 minutes ago. I 100% know that I am using the correct passphrase, but still it won't start the array complaining that it has the wrong passphrase.

Things I've tried to fix it

1) Put in other passphrases I may have used.  None of those worked. I'm 100% certain the passphrase I used first is the correct one so I'm not surprised.

2) Start the array with the device replace with "No device." It still complains of a wrong passphrase.

3) My passphrase contains a special character so did this, https://forums.unraid.net/bug-reports/prereleases/680-rc5-encryption-password-invalid-after-68-rc5-update-r700/?tab=comments#comment-6721. Still complains of a wrong passphrase.

4) Tried pulling the encrypted drive out and connecting to my laptop.  Now it complains of a wrong passphrase.

I think perhaps the part of the drive that stores the passpharse was overwritten or damaged somehow. In any even this is the only drive of the array that seems to not be working properly. 

Questions

1) Can I put in a new drive in the slot and then put in the passphrase and (assuming the parity is valid) rebuild the array? Or will it complain of a wrong passpharse again? This is the only encrypted drive in the array.

2) If I can't or should do that is there anyway to figure out what happened to the drive and try to recover it? Like I said, I am 100% certain I am putting in the correct passpharse, if it is complaining that it is wrong, it somehow was changed.

3) If the drive is lost and unrecoverable, what should I do to get the array back up? If the data is gone I can probably get most of it back. I'll have to be downloading for a while and figure out exactly what I lost, but it is replaceable. I'd like to not have to do that for the whole system however.

Thanks for your help.