yesterday my server sent the following fail event notice:

Personalities : [linear] [multipath] [raid0] [raid1] [raid6] [raid5]
[raid4] [raid10] md0 : active raid5 sda3[3](F) sdb2[1] sdc2[2] 775119872
blocks level 5, 256k chunk, algorithm 2 [3/2] [_UU]


the output from mdadm --detail /dev/md0

/dev/md0:
Version : 00.90
Creation Time : Tue Nov 13 18:54:53 2007
Raid Level : raid5
Array Size : 775119872 (739.21 GiB 793.72 GB)
Used Dev Size : 387559936 (369.61 GiB 396.86 GB)
Raid Devices : 3
Total Devices : 3
Preferred Minor : 0
Persistence : Superblock is persistent

Update Time : Wed Nov 9 12:16:03 2011
State : active, degraded
Active Devices : 2
Working Devices : 2
Failed Devices : 1
Spare Devices : 0

Layout : left-symmetric
Chunk Size : 256K

UUID : 5eeedfbe:638b34fc:f4b4498b:51f8baf9
Events : 0.544353

Number Major Minor RaidDevice State
0 0 0 0 removed
1 8 18 1 active sync /dev/sdb2
2 8 34 2 active sync /dev/sdc2

3 8 3 - faulty spare /dev/sda3

fdisk says about /dev/sda:

Platte /dev/sda: 400.1 GByte, 400088457216 Byte
255 Köpfe, 63 Sektoren/Spur, 48641 Zylinder
Einheiten = Zylinder von 16065 × 512 = 8225280 Bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x0f8000b1

Gerät boot. Anfang Ende Blöcke Id System
/dev/sda1 * 1 25 200781 83 Linux
/dev/sda2 26 392 2947927+ 82 Linux Swap / Solaris
/dev/sda3 393 48641 387560092+ fd Linux raid autodetect

The only shortly available spare device is a 1TB SATA drive.

smartctl on /dev/sda reports a healthy drive and /dev/sda1 is still available

What is the suggested way to get the array back working?
Does it make sense to "revert" the faulty state of /dev/sda?
How to partition the 1 TB drive to be able to grow the array after replacing all old drives with 1TB ones?

Thanks
Reinhard



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