So I get an email about my drive being disabled....I included the syslog for the drive...I'm running 5RC5. I stopped the array and added a drive that I had as a warm spare. I'm running preclear on the red balled drive as we speak. Little guidance on what to do with the drive.

 

smartctl -a -a /dev/sdd (--)
smartctl version 5.38 [i486-slackware-linux-gnu] Copyright (C) 2002-8 Bruce Allen
Home page is http://smartmontools.sourceforge.net/

=== START OF INFORMATION SECTION ===
Device Model:     SAMSUNG HD204UI
Serial Number:    S2H7JD2B227178
Firmware Version: 1AQ10001
User Capacity:    2,000,398,934,016 bytes
Device is:        In smartctl database [for details use: -P show]
ATA Version is:   8
ATA Standard is:  Not recognized. Minor revision code: 0x28
Local Time is:    Fri Jul 20 11:13:13 2012 EDT

==> WARNING: May need -F samsung or -F samsung2 enabled; see manual for details.

SMART support is: Available - device has SMART capability.
SMART support is: Enabled

=== START OF READ SMART DATA SECTION ===
SMART overall-health self-assessment test result: PASSED

General SMART Values:
Offline data collection status:  (0x00)	Offline data collection activity
				was never started.
				Auto Offline Data Collection: Disabled.
Self-test execution status:      (   0)	The previous self-test routine completed
				without error or no self-test has ever 
				been run.
Total time to complete Offline 
data collection: 		 (20820) seconds.
Offline data collection
capabilities: 			 (0x5b) SMART execute Offline immediate.
				Auto Offline data collection on/off support.
				Suspend Offline collection upon new
				command.
				Offline surface scan supported.
				Self-test supported.
				No Conveyance Self-test supported.
				Selective Self-test supported.
SMART capabilities:            (0x0003)	Saves SMART data before entering
				power-saving mode.
				Supports SMART auto save timer.
Error logging capability:        (0x01)	Error logging supported.
				General Purpose Logging supported.
Short self-test routine 
recommended polling time: 	 (   2) minutes.
Extended self-test routine
recommended polling time: 	 ( 255) minutes.
SCT capabilities: 	       (0x003f)	SCT Status supported.
				SCT Feature Control supported.
				SCT Data Table supported.

SMART Attributes Data Structure revision number: 16
Vendor Specific SMART Attributes with Thresholds:
ID# ATTRIBUTE_NAME          FLAG     VALUE WORST THRESH TYPE      UPDATED  WHEN_FAILED RAW_VALUE
  1 Raw_Read_Error_Rate     0x002f   100   100   051    Pre-fail  Always       -       563
  2 Throughput_Performance  0x0026   252   252   000    Old_age   Always       -       0
  3 Spin_Up_Time            0x0023   067   066   025    Pre-fail  Always       -       10198
  4 Start_Stop_Count        0x0032   099   099   000    Old_age   Always       -       1944
  5 Reallocated_Sector_Ct   0x0033   252   252   010    Pre-fail  Always       -       0
  7 Seek_Error_Rate         0x002e   252   252   051    Old_age   Always       -       0
  8 Seek_Time_Performance   0x0024   252   252   015    Old_age   Offline      -       0
  9 Power_On_Hours          0x0032   100   100   000    Old_age   Always       -       1488
10 Spin_Retry_Count        0x0032   252   252   051    Old_age   Always       -       0
11 Calibration_Retry_Count 0x0032   252   252   000    Old_age   Always       -       0
12 Power_Cycle_Count       0x0032   100   100   000    Old_age   Always       -       98
181 Unknown_Attribute       0x0022   252   252   000    Old_age   Always       -       0
191 G-Sense_Error_Rate      0x0022   100   100   000    Old_age   Always       -       1
192 Power-Off_Retract_Count 0x0022   252   252   000    Old_age   Always       -       0
194 Temperature_Celsius     0x0002   064   062   000    Old_age   Always       -       35 (Lifetime Min/Max 19/38)
195 Hardware_ECC_Recovered  0x003a   100   100   000    Old_age   Always       -       0
196 Reallocated_Event_Count 0x0032   252   252   000    Old_age   Always       -       0
197 Current_Pending_Sector  0x0032   252   252   000    Old_age   Always       -       0
198 Offline_Uncorrectable   0x0030   252   252   000    Old_age   Offline      -       0
199 UDMA_CRC_Error_Count    0x0036   200   200   000    Old_age   Always       -       0
200 Multi_Zone_Error_Rate   0x002a   100   100   000    Old_age   Always       -       14
223 Load_Retry_Count        0x0032   252   252   000    Old_age   Always       -       0
225 Load_Cycle_Count        0x0032   100   100   000    Old_age   Always       -       1980

SMART Error Log Version: 1
No Errors Logged

SMART Self-test log structure revision number 1
Num  Test_Description    Status                  Remaining  LifeTime(hours)  LBA_of_first_error
# 1  Short offline       Completed without error       00%      1483         -
# 2  Short offline       Completed without error       00%      1162         -

SMART Selective Self-Test Log Data Structure Revision Number (0) should be 1
SMART Selective self-test log data structure revision number 0
Warning: ATA Specification requires selective self-test log data structure revision number = 1
SPAN  MIN_LBA  MAX_LBA  CURRENT_TEST_STATUS
    1        0        0  Completed [00% left] (0-65535)
    2        0        0  Not_testing
    3        0        0  Not_testing
    4        0        0  Not_testing
    5        0        0  Not_testing
Selective self-test flags (0x0):
  After scanning selected spans, do NOT read-scan remainder of disk.
If Selective self-test is pending on power-up, resume after 0 minute delay.

disk1_syslog.txt

The drive looks fine. I expect it will pass the pre-clear and become the new spare. This looks more like a communications issue than a disk problem. Perhaps the SATA connection was loose. Your procedure is correct.

Thanks for the swift reply ... I will check the connections after the preclear and conduct a reboot.