If the rebuild fails again at about the same spot(24%), that usually indicates a punctured stripe or 1 of the remaining online drives has problems. If this is the case the only way to recover is to recreate the array and reinstall the os(or re-image the system) and restore from backup.
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by: charlestassePosted on 2009-10-30 at 11:06:00ID: 25705431
Based on what you have reported the issue may not be with the hard drive.
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When a drive failes to rebuild and replacing it with another drive that fails to rebuild at the same point indicates damage to the consistancy of the Array. This is indictive of a punchered stripe
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The only resolution is to save / image you data, delete the array and recreate it, restoring your data. This is not a perfect fit as the data that is corrupted by the puncher is not recoverable