The title definitely happened to me.

System boots off of a simple, separate disk.
Two 500GB disks (sdb, sdc) were mirrored with md, then a VG created, a LV, and 
ext3 on top.  Simple, worked great.  /etc/mdadm/mdadm.conf did NOT list the 
configuration, but rather depended on a scan to figure it all out every boot.  
I did not set this up.  I just ran mdadm and vgxxx lvxxx commands to create it 
all on install.  Never touched the .conf.

Upgraded 0810 to 0904.
This is where I get fuzzy, did not keep good records.

On boot, fsck failed saying that the volume did not exist.  
mdadm at various times has told me that sdb did not exist, had a bad 
superblock, and was in use by another process.  No doubt I caused some of my 
own problems.  At a point in the past on a re-install of 0810 I they were not 
recognized and I recovered by setting one of the mirrors to fail, removing it, 
and readding it.  Did not work this time.  I continued to fiddle, as well as 
learn the syntax of mdadm (man page confusing (to me)).

At all times mdadm --examine /dev/sdb (or sdc) told me that both mirrors
were fine / clean.

As I fiddled, one disk came on-line.  I rebooted, and it was gone.  I
got it back.  At one point I had two.  Fool, I rebooted.  Lost.  After
much fooling (wouldn't come back) I got one back.  Am backing up to a
non-md ext3 on a USB drive!  Plan to wipe the disks and reinstall from
scratch.

Error messages saying that /dev/sdb does not exist when I can dd blocks
from it, or that it is in use by another process when (1) I have not run
anything and (2) lsof does not show anything, and Statements that the
Superblock is bad on a mirror that has been running for six monthes, and
was healthy when I pushed the "upgrade" button and dead on reboot at the
end of the install process ... are not helpful at all!  Plus things were
inconsistent.

It sure looks like something buggy / flakey is happening.  I would
suspect flakey hardware except that the system has been stable for 6 or
8 years, including up until I pressed "Upgrade".  Two hours later, this.

Should I assume that 0904 is inherently stable, that this was just a
botched "upgrade" proceedure not covering something that was changed, or
should I re-install 0810?

Opinions and your rationale would be GREATLY appreciated.

-- 
mdadm software raid breaks  on intrepid-jaunty upgrade
https://bugs.launchpad.net/bugs/330298
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