This guide shows how to remove a failed hard drive from a Linux RAID1 array (software RAID), and how to add a new hard disk to the RAID1 array without losing data.
I do not issue any guarantee that this will work for you!
1 Preliminary Note
In this example I have two hard drives, /dev/sda and /dev/sdb, with the partitions /dev/sda1 and /dev/sda2 as well as /dev/sdb1 and /dev/sdb2.
/dev/sda1 and /dev/sdb1 make up the RAID1 array /dev/md0.
/dev/sda2 and /dev/sdb2 make up the RAID1 array /dev/md1.
/dev/sda1 + /dev/sdb1 = /dev/md0
/dev/sda2 + /dev/sdb2 = /dev/md1
/dev/sdb has failed, and we want to replace it.
2 How Do I Tell If A Hard Disk Has Failed?
If a disk has failed, you will probably find a lot of error messages in the log files, e.g. /var/log/messages or /var/log/syslog.
You can also run
cat /proc/mdstat
and instead of the string [UU] you will see [U_] if you have a degraded RAID1 array.
3 Removing The Failed Disk
To remove /dev/sdb, we will mark /dev/sdb1 and /dev/sdb2 as failed and remove them from their respective RAID arrays (/dev/md0 and /dev/md1).
First we mark /dev/sdb1 as failed:
mdadm –manage /dev/md0 –fail /dev/sdb1
The output of
cat /proc/mdstat
should look like this:
server1:~# cat /proc/mdstat
Personalities : [linear] [multipath] [raid0] [raid1] [raid5] [raid4] [raid6] [raid10]
md0 : active raid1 sda1[0] sdb1[2](F)
24418688 blocks [2/1] [U_]
md1 : active raid1 sda2[0] sdb2[1]
24418688 blocks [2/2] [UU]
unused devices: <none>
Then we remove /dev/sdb1 from /dev/md0:
mdadm –manage /dev/md0 –remove /dev/sdb1
The output should be like this:
server1:~# mdadm –manage /dev/md0 –remove /dev/sdb1
mdadm: hot removed /dev/sdb1
And
cat /proc/mdstat
should show this:
server1:~# cat /proc/mdstat
Personalities : [linear] [multipath] [raid0] [raid1] [raid5] [raid4] [raid6] [raid10]
md0 : active raid1 sda1[0]
24418688 blocks [2/1] [U_]
md1 : active raid1 sda2[0] sdb2[1]
24418688 blocks [2/2] [UU]
unused devices: <none>
Now we do the same steps again for /dev/sdb2 (which is part of /dev/md1):
mdadm –manage /dev/md1 –fail /dev/sdb2
cat /proc/mdstat
server1:~# cat /proc/mdstat
Personalities : [linear] [multipath] [raid0] [raid1] [raid5] [raid4] [raid6] [raid10]
md0 : active raid1 sda1[0]
24418688 blocks [2/1] [U_]
md1 : active raid1 sda2[0] sdb2[2](F)
24418688 blocks [2/1] [U_]
unused devices: <none>
server1:~# mdadm –manage /dev/md1 –remove /dev/sdb2
mdadm: hot removed /dev/sdb2
cat /proc/mdstat
server1:~# cat /proc/mdstat
Personalities : [linear] [multipath] [raid0] [raid1] [raid5] [raid4] [raid6] [raid10]
md0 : active raid1 sda1[0]
24418688 blocks [2/1] [U_]
md1 : active raid1 sda2[0]
24418688 blocks [2/1] [U_]
unused devices: <none>
Then power down the system:
shutdown -h now
and replace the old /dev/sdb hard drive with a new one (it must have at least the same size as the old one – if it’s only a few MB smaller than the old one then rebuilding the arrays will fail).
4 Adding The New Hard Disk
After you have changed the hard disk /dev/sdb, boot the system.
The first thing we must do now is to create the exact same partitioning as on /dev/sda. We can do this with one simple command:
sfdisk -d /dev/sda | sfdisk /dev/sdb
You can run
fdisk -l
to check if both hard drives have the same partitioning now.
Next we add /dev/sdb1 to /dev/md0 and /dev/sdb2 to /dev/md1:
mdadm –manage /dev/md0 –add /dev/sdb1
server1:~# mdadm –manage /dev/md0 –add /dev/sdb1
mdadm: re-added /dev/sdb1
mdadm –manage /dev/md1 –add /dev/sdb2
server1:~# mdadm –manage /dev/md1 –add /dev/sdb2
mdadm: re-added /dev/sdb2
Now both arays (/dev/md0 and /dev/md1) will be synchronized. Run
cat /proc/mdstat
to see when it’s finished.
During the synchronization the output will look like this:
server1:~# cat /proc/mdstat
Personalities : [linear] [multipath] [raid0] [raid1] [raid5] [raid4] [raid6] [raid10]
md0 : active raid1 sda1[0] sdb1[1]
24418688 blocks [2/1] [U_]
[=>……………….] recovery = 9.9% (2423168/24418688) finish=2.8min speed=127535K/sec
md1 : active raid1 sda2[0] sdb2[1]
24418688 blocks [2/1] [U_]
[=>……………….] recovery = 6.4% (1572096/24418688) finish=1.9min speed=196512K/sec
unused devices: <none>
When the synchronization is finished, the output will look like this:
server1:~# cat /proc/mdstat
Personalities : [linear] [multipath] [raid0] [raid1] [raid5] [raid4] [raid6] [raid10]
md0 : active raid1 sda1[0] sdb1[1]
24418688 blocks [2/2] [UU]
md1 : active raid1 sda2[0] sdb2[1]
24418688 blocks [2/2] [UU]
unused devices: <none>
That’s it, you have successfully replaced /dev/sdb!