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URGENT: Two USB array disks (24 and 25) in unstable state after physical replug — need recovery guidance

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Hello, looking for some guidance. I installed a coral tpu in an extra m2 slot and seemingly broke things.

Context:

Two WD My Passport USB external drives are/were in my array as disk24 and disk25.

Initial state after upgrade 7.1.4 → 7.2.4 + Coral install:

  • Disk25 (WD My Passport 25E2) was DISK_NP_DSBL — bridge appeared dead, /dev/sdb gave I/O errors

  • Disk24 (WD My Passport 25EA) was OK as /dev/sda

  • Shares not exposed (shfs not running)

Downgraded back to 7.1.4 — same shares issue persisted.

Physically unplugged and replugged both Passports into different USB ports. Now:

  • Disk25 is responding as /dev/sdag, but shows two partitions (sdag1 128MB, sdag2 3.6TB) which doesn't match Unraid's single-partition layout

  • Disk24 is completely missing — /dev/sda no longer exists as a block device

  • Array still STARTED, parity check available but canceled

  • shfs still not running

Need guidance on safe recovery — particularly worried that wrong assignment in WebGUI will trigger destructive parity rebuild.

Diagnostics zip attached.

Thanks for any help!

unraidmedia-diagnostics-20260419-1320.zip

  • Community Expert

USB not recommended for assigned disks for many reasons

  • Community Expert
1 minute ago, trurl said:

USB not recommended for assigned disks for many reasons

I especially don't recommend it when you have so many drives. In order to rebuild a disk, Unraid must be able to reliably read all other disks. So, even though each disk is an independent filesystem that can be read all by itself on any Linux, any unreliable disk in the array can make it difficult to reliably rebuild a different disk.

Since you have dual parity, that risk is reduced somewhat, since you would need 2 unreliable disks to cause problems for rebuilding another disk. But you do seem to have 2 unreliable disks.

Why do you have so many small disks anyway? Each additional disk is an additional point of failure.

If I were you, I would forget about those USB disks, except as Unassigned Devices, reset the array (New Config) without them, rebuild parity, and copy whatever is on those as Unassigned Devices to other disks in the array. When you eventually need more capacity, upsize disks, don't try to add more.

  • Community Expert

I didn't check SMART for any disk, since you have so many. Do any disks show SMART (👎) warning on the DASHBOARD page?

All disks are mounted, including the disabled/emulated disks, but you don't have any user shares. There seems to be something trying to access user shares before they have been created.

Disable Docker and VM Manager in Settings until you get all of this fixed.

Reboot in SAFE mode and post new diagnostics.

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