RAID does not like changes being made. Problems can arise in linux from just trying to rebuild the array with one disk missing. If the drive is there and say linux sees a write error or read error it will mark that dirty and should start using the spare. In your case it knows that f is part of the array. If d just isn't there this could create a problem. Even though it sees f and knows its a spare. I don't know why honestly. Just my experience. Your best bet is to replace d, leave f where it is. Then run the very first command you posted to verify it is rebuilding. If it does not automagically rebuild you will need to run the two commands i posted to force it to rebuild. That would be the smartest way of doing this. Although i should mention, there is always a chance that something else could go very wrong. RAID 5 is a piece of garbage. I do not understand why it was so popular. It puts the data on the disks like a tic tac toe game making it difficult to retrieve data. There are tools that can do this though. Knoppix has one. What you do is make images of the disks. Put the images on four more disks then have the tools try and rebuild the data. In your case i don't think that will work. Usually a four drive RAID 5 the fourth disk is the parity drive. Where the three disk RAID 5 parity is usually broken up between all three drives along with the data. So, on second thought backup probably isn't an option for you. You could try, there is no harm in making images of the drives before you try and rebuild it. At least that way, you can always send the images off for recovery if your significant other is making death threats. Then just blame it on the company, they screwed up, act really mad.