IT Dribble

Well before you power to replace the disk - can you be sure it will power back on?
Some distros have the bad habit of only install GRUB to one physical disk and if that disk dies…RAID wont save you (but a boot CD will…)

Firstly I like to confirm if /boot is configured in RAID 1. I then usually also install GRUB to all the physical disks via:

grub-install /dev/sda

and sdb and sdc etc. Then I power off the server and replace the disk.

After powering on the server, sometimes it won’t boot due to the new disk getting booted first, so make sure to select another disk in the BIOS boot-up menu.

After the operating system returns it’s a matter of recreating the partitions on the new disk, before trying to add it back into the RAID array. My servers all have the same disk sizes in the array and the same partition layouts, so to recreate them on the old disk I just perform:

sfdisk -d /dev/existing-disk | sfdisk /dev/new-disk

Confirm the new disks get the correct layout via:

cat /proc/partitions

and then add the partition back to the RAID array:

mdadm --add /dev/mdX /dev/sdXX

And then finally confirm its rebuilding via:

mdadm --detail /dev/mdX

OR

cat /proc/mdstat