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RSTe resync at every boot

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Hello,

 

We have a RAID10 of 4 SSDs on RSTe, under CentOS 6.5.

 

We had to re-seat disks. Now the array is always degraded and resyncs at every boot, the status in ctrl+i is alway "Rebuild", showing sdd as non-member but it's not possible to add it back. (sdd is totally zeroed)

 

The main issue: the mdadm --examine and cat /proc/mdstat are different.

 

mdadm: [Volume0:1]: Slots : [_UU_], This Slot : 0 (out-of-sync), Map State : degraded, Dirty State : dirty

 

mdstat: [4/3] [UUU_]

 

At reboot, it starts a resync with sda  - so the mdstat shows [_UU_] too but when resync finishes it turns to [UUU_] and won't start resync to sdd.

 

We can add or remove the sdd, but nothing happens. When sdd is added to md0 (container) mdstat --examine often just hangs.

 

When sdd is not added to md0, examine shows it like this:

  Disk03 Serial : 8400X5800RGN:0

          State : active failed

             Id : ffffffff

 

We can't stop array as it's the root FS.

 

 

How can we fix this?


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