This is a system I inherited...

I looked, and there are several drives of this type already in the array. 
Including ones I have not replaced. However, they show a separate pattern...

[root@sapphire ~]# sfdisk --list /dev/sdd

Disk /dev/sdd: 121601 cylinders, 255 heads, 63 sectors/track
Warning: The partition table looks like it was made
  for C/H/S=*/81/63 (instead of 121601/255/63).
For this listing I'll assume that geometry.
Units = cylinders of 2612736 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sdd1          0+ 382818- 382819- 976761560   fd  Linux raid autodetect
                end: (c,h,s) expected (1023,80,63) found (769,80,63)
/dev/sdd2          0       -       0          0    0  Empty
/dev/sdd3          0       -       0          0    0  Empty
/dev/sdd4          0       -       0          0    0  Empty

This is what the new drive looks like (with no partition table):

[root@sapphire ~]# sfdisk --list /dev/sdk

Disk /dev/sdk: 121601 cylinders, 255 heads, 63 sectors/track
Units = cylinders of 8225280 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sdk1          0       -       0          0    0  Empty
/dev/sdk2          0       -       0          0    0  Empty
/dev/sdk3          0       -       0          0    0  Empty
/dev/sdk4          0       -       0          0    0  Empty

Why it won't partition out to 121601 cylinders in fdisk is somewhat baffling...

I realize I may have done something stupid, since the last time I swapped a 
disk into this array, I now remember that I used sfdisk with the -force option 
to shove a partition table from one another drive onto the it, probably to 
resolve a similar problem without fully realizing the implications. I'm 
wondering if the previous admin did the same thing, only using a different 
source partition table, given the output from sfdisk above? I'm thinking that 
the WD1002FBYS-0 is actually, natively, one sector larger than its descendant, 
the WD1003FBYX-0, and that shoving an invalid partition table onto it won't 
matter... except when the system attempts to write to that last sector. At 
which point, I have no idea what is going to happen.

I noticed that the drive I previously swapped in, that obviously had some kind 
of partitioning issue, is identical to the new drive, and not the existing 
ones, when I do "fdisk -l", even though it is the same model and version number 
as existing drives.

the unit size is different for each of the new drives:

Units = cylinders of 16065 * 512 = 8225280 bytes

Thoughts? What am I missing here? I seriously miss the simplicity of swapping a 
replacement drive into a hardware raid array. Ugh.

Thomas

P.S. Here's a complete listing of the drives in the array... /dev/sdb is the 
drive I last swapped into the array... that's the only one that doesn't output 
this message... I copied it thusly: "sfdisk -d /dev/sdc | sfdisk --force 
/dev/sdb"

Disk /dev/sdb: 121601 cylinders, 255 heads, 63 sectors/track
Units = cylinders of 8225280 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sdb1          0+ 121601- 121602- 976761560   fd  Linux raid autodetect
/dev/sdb2          0       -       0          0    0  Empty
/dev/sdb3          0       -       0          0    0  Empty
/dev/sdb4          0       -       0          0    0  Empty

Disk /dev/sdc: 121601 cylinders, 255 heads, 63 sectors/track
Warning: The partition table looks like it was made
  for C/H/S=*/81/63 (instead of 121601/255/63).
For this listing I'll assume that geometry.
Units = cylinders of 2612736 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sdc1          0+ 382818- 382819- 976761560   fd  Linux raid autodetect
                end: (c,h,s) expected (1023,80,63) found (769,80,63)
/dev/sdc2          0       -       0          0    0  Empty
/dev/sdc3          0       -       0          0    0  Empty
/dev/sdc4          0       -       0          0    0  Empty

Disk /dev/sdd: 121601 cylinders, 255 heads, 63 sectors/track
Warning: The partition table looks like it was made
  for C/H/S=*/81/63 (instead of 121601/255/63).
For this listing I'll assume that geometry.
Units = cylinders of 2612736 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sdd1          0+ 382818- 382819- 976761560   fd  Linux raid autodetect
                end: (c,h,s) expected (1023,80,63) found (769,80,63)
/dev/sdd2          0       -       0          0    0  Empty
/dev/sdd3          0       -       0          0    0  Empty
/dev/sdd4          0       -       0          0    0  Empty

Disk /dev/sde: 121601 cylinders, 255 heads, 63 sectors/track
Warning: The partition table looks like it was made
  for C/H/S=*/81/63 (instead of 121601/255/63).
For this listing I'll assume that geometry.
Units = cylinders of 2612736 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sde1          0+ 382818- 382819- 976761560   fd  Linux raid autodetect
                end: (c,h,s) expected (1023,80,63) found (769,80,63)
/dev/sde2          0       -       0          0    0  Empty
/dev/sde3          0       -       0          0    0  Empty
/dev/sde4          0       -       0          0    0  Empty

Disk /dev/sdf: 121601 cylinders, 255 heads, 63 sectors/track
Warning: The partition table looks like it was made
  for C/H/S=*/81/63 (instead of 121601/255/63).
For this listing I'll assume that geometry.
Units = cylinders of 2612736 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sdf1          0+ 382818- 382819- 976761560   fd  Linux raid autodetect
                end: (c,h,s) expected (1023,80,63) found (769,80,63)
/dev/sdf2          0       -       0          0    0  Empty
/dev/sdf3          0       -       0          0    0  Empty
/dev/sdf4          0       -       0          0    0  Empty

Disk /dev/sdg: 121601 cylinders, 255 heads, 63 sectors/track
Warning: The partition table looks like it was made
  for C/H/S=*/81/63 (instead of 121601/255/63).
For this listing I'll assume that geometry.
Units = cylinders of 2612736 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sdg1          0+ 382818- 382819- 976761560   fd  Linux raid autodetect
                end: (c,h,s) expected (1023,80,63) found (769,80,63)
/dev/sdg2          0       -       0          0    0  Empty
/dev/sdg3          0       -       0          0    0  Empty
/dev/sdg4          0       -       0          0    0  Empty

Disk /dev/sdh: 121601 cylinders, 255 heads, 63 sectors/track
Warning: The partition table looks like it was made
  for C/H/S=*/81/63 (instead of 121601/255/63).
For this listing I'll assume that geometry.
Units = cylinders of 2612736 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sdh1          0+ 382818- 382819- 976761560   fd  Linux raid autodetect
                end: (c,h,s) expected (1023,80,63) found (769,80,63)
/dev/sdh2          0       -       0          0    0  Empty
/dev/sdh3          0       -       0          0    0  Empty
/dev/sdh4          0       -       0          0    0  Empty

Here's the output of fdisk -l:

Disk /dev/sdb: 1000.2 GB, 1000204886016 bytes
255 heads, 63 sectors/track, 121601 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0xbb36e923

   Device Boot      Start         End      Blocks   Id  System
/dev/sdb1               1      121602   976761560   fd  Linux raid autodetect

Disk /dev/sdc: 1000.2 GB, 1000204886016 bytes
81 heads, 63 sectors/track, 382818 cylinders
Units = cylinders of 5103 * 512 = 2612736 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0xc3ec2e6c

   Device Boot      Start         End      Blocks   Id  System
/dev/sdc1               1      382819   976761560   fd  Linux raid autodetect

Disk /dev/sdd: 1000.2 GB, 1000204886016 bytes
81 heads, 63 sectors/track, 382818 cylinders
Units = cylinders of 5103 * 512 = 2612736 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0xb29dc924

   Device Boot      Start         End      Blocks   Id  System
/dev/sdd1               1      382819   976761560   fd  Linux raid autodetect

Disk /dev/sde: 1000.2 GB, 1000204886016 bytes
81 heads, 63 sectors/track, 382818 cylinders
Units = cylinders of 5103 * 512 = 2612736 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x63f0d2be

   Device Boot      Start         End      Blocks   Id  System
/dev/sde1               1      382819   976761560   fd  Linux raid autodetect

Disk /dev/sdf: 1000.2 GB, 1000204886016 bytes
81 heads, 63 sectors/track, 382818 cylinders
Units = cylinders of 5103 * 512 = 2612736 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x354099fb

   Device Boot      Start         End      Blocks   Id  System
/dev/sdf1               1      382819   976761560   fd  Linux raid autodetect

Disk /dev/sdg: 1000.2 GB, 1000204886016 bytes
81 heads, 63 sectors/track, 382818 cylinders
Units = cylinders of 5103 * 512 = 2612736 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0xe482e1ae

   Device Boot      Start         End      Blocks   Id  System
/dev/sdg1               1      382819   976761560   fd  Linux raid autodetect

Disk /dev/sdh: 1000.2 GB, 1000204886016 bytes
81 heads, 63 sectors/track, 382818 cylinders
Units = cylinders of 5103 * 512 = 2612736 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0xad1ef785

   Device Boot      Start         End      Blocks   Id  System
/dev/sdh1               1      382819   976761560   fd  Linux raid autodetect

Here's the new disk... the output matches the drive I previously swapped in 
/dev/sdb... the unit size is different for each of the new drives:

Units = cylinders of 16065 * 512 = 8225280 bytes


[root@system1 ~]# fdisk -l /dev/sdk

Disk /dev/sdk: 1000.2 GB, 1000204886016 bytes
255 heads, 63 sectors/track, 121601 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x560266d3

   Device Boot      Start         End      Blocks   Id  System


From: [email protected] 
[mailto:[email protected]] On Behalf Of Thomas 
Leavitt
Sent: Tuesday, March 29, 2016 12:11 PM
To: [email protected]
Subject: Identical disks, different # sectors

General Linux question, y'all seem very helpful generally, hope this is o.k.

I noticed that a disk in an mdadm software RAID10 array had been automatically 
removed. I pulled it, popped in a new disk that is the EXACT same model as 
several disks already in the system and the array... ran fdisk on it, created a 
partition, put a disk label on it, then tried to add it, and got "not large 
enough to join array" as an error message. It seems like the new disk is one 
sector smaller. Am I just out of luck with this disk, because the firmware has 
decided to nuke one sector? Makes buying spares, and having them on hand, 
pretty dicey if such is the case. Have two on order at the moment.

This is the second time I've been led a merry go round simply trying to replace 
a disk in this array, it is seriously souring me on mdadm and software RAID in 
general (not that I was a big fan of it anyway).

Any suggestions? This is part of a dual clustered system, two RAID10 arrays in 
a glusterfs, so one missing drive isn't a crisis, but obviously less than ideal.

Regards,
Thomas Leavitt

[root@system1 ~]# fdisk -l /dev/sdb1

Disk /dev/sdb1: 1000.2 GB, 1000203837440 bytes
255 heads, 63 sectors/track, 121601 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x00000000

[root@system1 ~]# fdisk -l /dev/sdk1

Disk /dev/sdk1: 1000.2 GB, 1000202241024 bytes
255 heads, 63 sectors/track, 121600 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x00000000


lshw
description: ATA Disk
                   product: WDC WD1003FBYX-0
                   vendor: Western Digital
                   physical id: 0.b.0
                   bus info: scsi@0:0.11.0<mailto:scsi@0:0.11.0>
                   logical name: /dev/sdb
                   version: 1V02
                   serial: WD-WCAW35919858
                   size: 931GiB (1TB)
                   capacity: 931GiB (1TB)

description: ATA Disk
                   product: WDC WD1003FBYX-0
                   vendor: Western Digital
                   physical id: 0.e.0
                   bus info: scsi@0:0.14.0<mailto:scsi@0:0.14.0>
                   logical name: /dev/sdk
                   version: 1V02
                   serial: WD-WCAW33395036
                   size: 931GiB (1TB)
                   capacity: 931GiB (1TB)

[root@sapphire ~]# mdadm --manage /dev/md3 --add /dev/sdk1
mdadm: /dev/sdk1 not large enough to join array

--
Thomas Leavitt ([email protected]<mailto:[email protected]>)
Interim Sr. Linux IT Consultant (880 IT Services)
831-469-3382 (Google Voice forwards to 880 IT cell, accepts SMS)
1-408-454-4569 (desk)

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