I sent a customer a replacement drive for a failed 73GB hard drive that was part of a five disk RAID5 array. When they replaced the drive it somehow changed the array to be a four disk RAID5 with the replacement as a hot spare. Does anyone know of a procedure to force the drive to rebuild as part of the RAID5 instead of a hot spare and not effect the data? We tried several times by rebooting into the OS with just four drives seated and then reseating the replacement once in the OS but it failed after 15min. This is the second drive that was sent for this. The first failed also and we thought it might be a faulty drive. The server is a Dell PowerEdge 2650 with a 3Di controller. OS is Win Server 2003 running Dell OpenManage.