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Intel Matrix  Storage RAID1 rebuild issues

SimonShaw asked
Last Modified: 2012-08-22
I have a custom server which has 2x500Gb SATA attached to an Intel ICH9R controller.  Intel storage manager s/w is installed.
First, SATA port 0 reported an error in POST, then a little while later the drive failed.  It continued to run with the RAID volume degraded.  Then SATA port 1 started reporting an error in POST, but the system was still booting and running okay.
Replaced drive on port 0, and used storage manager to rebuild the drive.  Didn't take very long - about 2 hours and all seemed normal.  Installed updates and rebooted okay.
After another reboot, the machine got to a mouse pointer on a black screen, then rebooted itself.  Last known good was no use.  Disconnected disk on port 1 (impending failure) and got the same result.  Disconnected disk on port 0 (newly added) and it booted, but now with SMART error as well as POST error reported on the remaining disk on port 1.
Doing another backup now!
Not at all sure of next steps.  It seems I have
- an older disk on port 1 possibly about to fail but which boots,
- a new one on port 0 which doesn't boot!
Advice appreciated.
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