And the story continues… The spare drive I bought on 2016/06/27 was defective as well. As it turned out, it wasn’t even new! The Seagate Warranty Check said: “Out of Warranty” 🙁
I contacted Amazon and they immediately forwarded my request to the retailer (2016/09/03 4:44pm). Let’s what happens…
I ordered a new drive on 2016/08/27 6:50pm, this time a Hitachi 4TB drive (HGST 0S03665 4TB Deskstar), but I made a mistake: I chose a Packstation as delivery address, even though I don’t have an account (yet), so the parcel was returned to sender (Amazon). At first I couldn’t make sense of the delivery status: Amazon said that the parcel was successfully delivered, but DHL said that it had been returned to sender. A short phone call cleared things up: The drive was indeed returned and I received a credit note (2016/09/02 about 1:40pm).
Later that day I ordered another Hitachi 4TB drive with the same retailer which arrived early next day (2016/09/03 about 9:00am). Unfortunately there wasn’t much time to waste: I had to fail the spare drive hard, because it hung the SATA bus during rebuild:
# mdadm --manage /dev/md1 --fail /dev/sdi
At first I thought that munin -> smartctl -a caused the hangs, but disabling it didn’t help.
While replacing the failed drive I burnt my fingers from the heat, so I set the fan to maximum when I turned Hadante on again. Rebuild is 42% done, still 11 hours to go as of 2016/09/03 5:25pm. No issues yet, keeping my fingers crossed 🙂
Anyway, this is a photo of the anti-static bag the Hitachi drive came in (SN: P4HU95KB):
(Update 2016/09/04 06:56AM): Yeah! The rebuild is done! Hopefully safe again! The obnam LV shut down due to xfs errors, but that’s something I can live with. Maybe it’s the aftermath for force-assembling the array…