I've got a similar problem trying to break down a RAID1 array to use the
individual partitions for swap. From what I understand the array was
created during installation and marked as swap, then had a single
partition removed from it (currently activated as swap).

$ uname -a
Linux adlai 2.6.24-23-server #1 SMP Mon Jan 26 00:55:21 UTC 2009 i686 GNU/Linux

$ cat /etc/lsb-release 
DISTRIB_ID=Ubuntu
DISTRIB_RELEASE=8.04
DISTRIB_CODENAME=hardy
DISTRIB_DESCRIPTION="Ubuntu 8.04.2"

$ mdadm --version
mdadm - v2.6.3 - 20th August 2007

$ sudo fdisk -l

Disk /dev/sda: 500.1 GB, 500107862016 bytes
255 heads, 63 sectors/track, 60801 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Disk identifier: 0x9e169e16

   Device Boot      Start         End      Blocks   Id  System
/dev/sda1   *           1         973     7815591   fd  Linux raid autodetect
/dev/sda2             974       31367   244139805   fd  Linux raid autodetect
/dev/sda3           60668       60801     1076355   82  Linux swap / Solaris
/dev/sda4           31368       60667   235352250   fd  Linux raid autodetect

Partition table entries are not in disk order

Disk /dev/sdb: 500.1 GB, 500107862016 bytes
255 heads, 63 sectors/track, 60801 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Disk identifier: 0x07a6b49b

   Device Boot      Start         End      Blocks   Id  System
/dev/sdb1   *           1         973     7815591   fd  Linux raid autodetect
/dev/sdb2             974       31367   244139805   fd  Linux raid autodetect
/dev/sdb3           60668       60801     1076355   82  Linux swap / Solaris
/dev/sdb4           31368       60667   235352250   fd  Linux raid autodetect

Partition table entries are not in disk order

(snip)

$ cat /proc/mdstat 
Personalities : [linear] [multipath] [raid0] [raid1] [raid6] [raid5] [raid4] 
[raid10] 
md3 : active raid1 sda2[0] sdb2[1]
      244139712 blocks [2/2] [UU]
      
md4 : active raid1 sda4[0] sdb4[1]
      235352128 blocks [2/2] [UU]
      
md2 : active raid1 sdb3[1]
      1076288 blocks [2/1] [_U]
      
md0 : active raid1 sda1[0] sdb1[1]
      7815488 blocks [2/2] [UU]
      
unused devices: <none>

$ swapon -s
Filename                                Type            Size    Used    Priority
/dev/sda3                               partition       1076344 112     -1

$ sudo mdadm --stop /dev/md2
mdadm: fail to stop array /dev/md2: Device or resource busy

$ sudo mdadm /dev/md2 --fail --verbose /dev/sdb3
mdadm: set /dev/sdb3 faulty in /dev/md2

$ sudo mdadm /dev/md2 --remove --verbose /dev/sdb3
mdadm: hot remove failed for /dev/sdb3: Device or resource busy

The only other thing I can think of is booting from a livecd and zeroing
the superblock / running mkswap, but that will probably take a while to
schedule downtime for.

-- 
cannot stop RAID1
https://bugs.launchpad.net/bugs/371338
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