Hi folks, I updated to Unraid OS 7.1.3 (from 7.1.0) this morning and immediately ran into an issue. After I installed and rebooted, it wouldn't let me start the array, saying that disk 1 was 'wrong' and the array was 'Stopped. Replacement disk is too small'. It's the same disk as before the update.

What troubleshooting steps should I take here? To start, the SMART short self-test came back clean. Next I tried creating a new config and now the disk is 'Unmountable: wrong or no file system'.

I'm super new to getting under the hood with systems like this - I got Unraid running and it worked fine for a year, but I migrated (the drives + usb) to a new machine a month ago and it's been giving me trouble ever since. Everything seemed to be working fine before the update, I shouldn't have tested my luck 😅

Thanks in advance!

tower-diagnostics-20250605-1318.zip

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11 hours ago, Wild Blue said:

Hi folks, I updated to Unraid OS 7.1.3 (from 7.1.0)

I assume you mean 7.0.x?

If yes, there's a disk with an invalid partition, standard way to fix it would be to rebuild, but if you are comfortable using the CLI, there is usually a faster way.

7 hours ago, JorgeB said:

I assume you mean 7.0.x?

You're correct! Sorry for the typo

7 hours ago, JorgeB said:

but if you are comfortable using the CLI, there is usually a faster way.

I've been learning how to use it, so might as well take the opportunity to practice. What is the faster way?

Did you remove the diags? Unable to download them again, and before I was at home, so don't have the zip here.

That's weird, I didn't remove them. Uploading again to be on the safe side.

tower-diagnostics-20250605-1318.zip

It looks like it's a forum issue, I'll try again in a few.

Stop the array, and type:

sgdisk -o -a 8 -n 1:32K:0 /dev/sdX

Replace X with the correct disk1 letter, it was sde as of last diags, but it can change with a reboot, then reboot, after that Unraid will complain again that disk1 is "wrong", do another new config, start the array, and it should now work again.

Thank you! Everything seems to be back where it's supposed to be. I super appreciate your help.

I'm having the same issue with disk2 after 7.0.x→7.1.4. Does this fix affect existing data, or can I just slap it in?

17 hours ago, Chandelin said:

I'm having the same issue with disk2 after 7.0.x→7.1.4. Does this fix affect existing data, or can I just slap it in?

Please post the diagnostics.

Thank you for your time.

Tower-diagnostics-20250622-0832.zip

It appears to have a non-standard partition, unassign that disk and start the array, if the emulated disks mounts and contents look correct, assign it again and start the array to begin rebuilding, then grab and post new diags.

28 minutes ago, JorgeB said:

unassign that disk and start the array, if the emulated disks mounts and contents look correct...

By this, you mean I open the folders that were on that disk and see the contents? I did this and did see the contents all accounted for. I did not know it would emulate the missing disks information, but seeing this all, it makes sense.

I'll stop the array and reassign the drive.

7 minutes ago, Chandelin said:

By this, you mean I open the folders that were on that disk and see the contents?

You can just do a cursory check, typically, when the emulated disk mounts, all content should be there.

It shows disk 1 and 2 as red x now, and it says the rebuild is paused. I didn't touch anything though after reassigning the drive, and hitting start. The dashboard and shares tabs are blank screens now. So I'm nervous.

Tower-diagnostics-20250623-0925.zip

Disk2 dropped offline, this is typically a power/connection issue.

Hmmm the PSU is more than sufficient, new, and the connections have shown no issues. I've had connection issues before with the Sata. You were the one to help me before. Maybe I am having mobo issues and just haven't seen anything blatant enough to realize it.

6 hours ago, JorgeB said:

Disk2 dropped offline, this is typically a power/connection issue.

What can I do from here then? I'm afraid to suggest restart it or hit stop then start again because it had started the read check for the rebuild.

I would replace cables for those disks, since disk1 is also still showing ATA errors, do they share a power splitter or something?

Four of my drives share a power cable and three of them share data connection on a PCIe slot. Both power and data for the two red x drives are shared in some way with my no issue drives. This is so odd. I have cleaned my case and dusted the cable connections. Moved some around. All still visible in the Main tab. I am doing a rebuild now on both drives. Couple hours to go. I did some SMART tests and didn't come back with anything on either drive.

Any errors post new diags.

No errors that I can see.

Tower-diagnostics-20250627-0058.zip

Hi, I upgraded from 7.0.0 to 7.1.4 and got the "Replacement Disk Too Small" error. The array was working fine on 7.0.0.

My array consists of one data disk (sdb, disk1) and one parity disk (sdc). Disk1 is not mountable since the Unraid update. The parity disk is fine and mountable.

When starting the array, I see in the logs "disk1: mount error: wrong or no file System".

When mounting disk1 with the unassigned devices plugin, the logs show the error "XFS (sdb1): last sector read failed" and "Mount of 'sdb1' failed: 'mount: /mnt/disks/ZW62YC07: can't read superblock on /dev/sdb1."

For both drives, the SMART test shows no errors.

I have reset the configuration in Tools -> New config thinking the file system would be rebuilt from the parity drive. Unraid now warns me regarding the parity drive that "All existing data on this device will be OVERWRITTEN when array is Started", so I did not start the array yet.

I have the most important data backed up somewhere else, but can't back up my movies collection due to its size. A data loss on both drives would be annoying (having to re-download media), but not devastating.

What is the best course of action now? Should I try fixing the file system on disk1 or copy the entire file system from parity to disk1? I did not run the above mentioned commands, as I am not sure if the root cause is the same.

diagnostics-20250907-1216.zip

1 hour ago, vasike6904 said:

I have reset the configuration in Tools -> New config thinking the file system would be rebuilt from the parity drive.

When you do this you get an explicit message telling you that you will not be able to rebuild data.

1 hour ago, vasike6904 said:

Hi, I upgraded from 7.0.0 to 7.1.4 and got the "Replacement Disk Too Small" error. The array was working fine on 7.0.0.

The partition is not using the whole disk, v7 didn't care about that, but v7.1 will use the actual partition with the array stopped type:

sgdisk -o -a 8 -n 1:32K:0 /dev/sdX

Replace X with the correct disk1 identifier, then reboot. Disk1 will show as wrong again, do another new config and start the array, post new diags if it still doesn't mount.