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Issues with unmountable disk after data rebuild

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In my unraid system i replaced a 1tb drive with a 4tb. I was able to format, mount and assign the 4tb to disk3 replacing the 1tb. I started the array, it started the data rebuild. after 12 hours that process completed but now the drive is unmountable. I have tried to repair the xfs and got a report that it was successfully repaired. I rebooted the system and the drive is unmountable again. I have tried this with 2 different 4tb drives. How do I fix this?

the-matrix-diagnostics-20250424-2222.zip

  • Community Expert

Format is never part of rebuild. Sounds like you may have formatted it before actually assigning it though. Which would be pointless but not a disaster.

 

Did you do the repair from the webUI with the FIX button?

 

Can't tell anything about your filesystems since the array wasn't started in normal mode when you took those diagnostics.

 

And the diagnostics were taken after reboot, so can't tell what happened before that.

 

Start the array in normal mode and post new diagnostics.

  • Author
35 minutes ago, trurl said:

Format is never part of rebuild. Sounds like you may have formatted it before actually assigning it though. Which would be pointless but not a disaster.

 

Did you do the repair from the webUI with the FIX button?

 

Can't tell anything about your filesystems since the array wasn't started in normal mode when you took those diagnostics.

 

And the diagnostics were taken after reboot, so can't tell what happened before that.

 

Start the array in normal mode and post new diagnostics.

 

I will get a new diagnostics file. I started a fix from the webUI about an hour ago. I still have the animation on the screen. I haven't ever needed to do this so i am not sure how long it should take.

 

 

  • 2 weeks later...
  • Community Expert

Diags are not available, try again.

  • Community Expert

Disk3 appears to be failing, run an extended SMART test.

  • Author

Yes, I get a read failure. I will have a 2tb that I can replace it with, so I will have to shrink my array.

  • Community Expert
4 hours ago, sublevel4 said:

I will have a 2tb that I can replace it with, so I will have to shrink my array.

Normally, when we say "shrink the array", we mean fewer disks, not smaller disks.

 

You can't rebuild to a smaller disk.

  • Author

I was able to move the data off the drive. From my understanding(please correct me if i am wrong) i can then go through a process to remove that drive and rebuild the parity based on the remaining drives, correct? I have 4 2tb drives that are old but not a lot of hours.

  • Author

Thank you for your time and assistance.

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