Found the problem - brick on the other server had attributes set. Looks like 
once a brick has been used in the volume, after replacing once the brick comes 
back online, it cannot be re-used in the volume as it has the information left 
over.

From: [email protected] 
[mailto:[email protected]] On Behalf Of Prasad, Nirmal
Sent: Monday, July 28, 2014 9:16 PM
To: [email protected]
Subject: Re: [Gluster-users] Replace brick of failed server - 3.5.1

Based on the logs - this is what it gets, can someone shed some light on this.

[2014-07-28 17:06:43.467045] D 
[glusterd-op-sm.c:3008:glusterd_op_ac_send_stage_op] 0-management: Sent stage 
op request for 'Volume Replace brick' to 44 peers
[2014-07-28 17:06:43.467062] D 
[glusterd-op-sm.c:3013:glusterd_op_ac_send_stage_op] 0-management: Returning 
with 0
[2014-07-28 17:06:43.467075] D 
[glusterd-utils.c:6111:glusterd_sm_tr_log_transition_add] 0-management: 
Transitioning from 'Lock sent' to 'Stage op sent' due to event 
'GD_OP_EVENT_ALL_ACC'
[2014-07-28 17:06:43.467105] D 
[glusterd-utils.c:6113:glusterd_sm_tr_log_transition_add] 0-management: 
returning 0
[2014-07-28 17:06:43.467157] E [glusterd-rpc-ops.c:773:__glusterd_stage_op_cbk] 
0-management: Received stage RJT from uuid: 9edaaf4c-2f74-4242-b7cf-8320edf61f58
[2014-07-28 17:06:43.467178] D 
[glusterd-utils.c:5439:glusterd_friend_find_by_uuid] 0-management: Friend 
found... state: Peer in Cluster
[2014-07-28 17:06:43.467207] D 
[glusterd-op-sm.c:5640:glusterd_op_sm_inject_event] 0-management: Enqueue 
event: 'GD_OP_EVENT_RCVD_RJT'
[2014-07-28 17:06:43.467222] D [glusterd-op-sm.c:5717:glusterd_op_sm] 
0-management: Dequeued event of type: 'GD_OP_EVENT_RCVD_RJT'
[2014-07-28 17:06:43.467236] D 
[glusterd-op-sm.c:3602:glusterd_op_ac_stage_op_failed] 0-management: Returning 0
[2014-07-28 17:06:43.467248] D 
[glusterd-utils.c:6111:glusterd_sm_tr_log_transition_add] 0-management: 
Transitioning from 'Stage op sent' to 'Stage op failed' due to event 
'GD_OP_EVENT_RCVD_RJT'

From: 
[email protected]<mailto:[email protected]> 
[mailto:[email protected]] On Behalf Of Prasad, Nirmal
Sent: Monday, July 28, 2014 7:35 PM
To: [email protected]<mailto:[email protected]>
Subject: Re: [Gluster-users] Replace brick of failed server - 3.5.1

Error:
volume replace-brick: failed: brick: 192.168.24.57:/var/gluster/data does not 
exist in volume: gl_disk


From: Prasad, Nirmal
Sent: Monday, July 28, 2014 7:35 PM
To: [email protected]<mailto:[email protected]>
Subject: Replace brick of failed server - 3.5.1

Used to work in 3.5.0 - Have a completely failed server in a replica set of 3 - 
attempting to remove it and replace with another node fails.

How do I achieve the same result?

gluster volume replace-brick gl_disk 192.168.24.57:/var/gluster/data 
192.168.24.12:/var/gluster/data commit force
volume replace-brick: failed: brick: 10.238.24.57:/var/gluster/data does not 
exist in volume: gl_disk

It is not practical to assume that the dead node will always be available - if 
it has completely crashed - it may never come back.

Thanks
Regards
Nirmal
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