Can't rebuild RAID5 with new drive, RR642L HighPoint

Wiznaz

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I have been running 4x4TB in Raid5 successfully for the past 2-3 years in my Sans Digital 5-bay TowerRAID. In the beginning, I started with 3 disks and was able to expand the raid to a 4th disk. As of last week, I got the error beep and the problem was one of the original disks failed (Seagate). So I test the connectors & power, then pulled the drive, tested it solo and verified it was damaged.

So I purchased a 4TB WD Blue drive on sale to use as it's replacement. I originally had Auto-Rebuild enabled so I gave it 6 days to see if it would rebuild on it's own but it hasn't. I followed the High Point "How to Resolve a Critical RAID Status" PDF but I keep getting an error when I attempt to add the spare drive. When using their web interface, I see the spare drive in the Logical Device Information section but when I add it to the Raid, it give me the error message and then the drive moves to the Physical Drive Information section. This is the error:

"Failed to add Disk 'Device_1_E1_4'(Location: 1/E1/4) to array 'RAID_5_0'."

When booting into their DOS interface, I notice the new drive (1-1/4) is .03 GB smaller than the others. Is this it's reasoning for the drive being rejected? I wish the event log would be more in-depth.

Any help would be appreciated. Thanks!

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Wiznaz

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Hmm, but they are all 4TB drives. Is there anyway to correct this by adjusting the new disk's partition size, or re-partitioning the existing drives to have .03 GB smaller?
 

Wiznaz

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I attempted to shrink the raid partition 3 times now. It takes 8+ hours to perform and every time I check, the partition size stayed exactly the same. Is it common that drives are different sizes even though they are advertised as 1TB, 2TB, 4TB etc?