How to add a unnassigned drive to an existing array.

One of our customers has a Hp Proliant DL380 G7 Server running SBS2011 STD.

One of the drives went bad on the first logical drive. We have 2 total.
We ended up taking out the Second bay that had the optical drive and added a second drive box to add more storage space.
We added a SAS array expansion card and everything worked smoothly.
 We had set a spare drive and that became active.

When the drive went bad we got a replacement and Hot swapped it. The new drive will not add itself to the array.
it shows in the array configuration utility as unassigned. But the spare is still active which is good. and still shows bay 6 with a red x.

First thing i did which HP walked me through is powering off the server detaching  the hard drive back pane and turning master controller switch 6 to on and booting up. and it was suppose to fix the issue. but it did not work.

HP ended up sending one of their technicians down to troubleshoot it. He did pretty much everything I could think of.
1. replaced the mainboard
2. replaced the wires
3. replaced the SAS expansion card
4. replaced the hard drive backpane.
5. tried a few new hard drives.
6. updated firmware on the Controller, expansion card, the HD backpane, and the drive itself.

Nothing worked

Has anyone ever had this issue before where you didn't have to blow the array and restore or does that sound like the only option that is left on the table?
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noxchoGlobal Support CoordinatorCommented:
Have you tried to clean the disk status via Array Configuration Utility? It can be that the problem lays on the surface.
At the last resort you can take backup of existing RAID configuration and then reconfigure the RAID from scratch and restore back from backup.
BBraytonAuthor Commented:
How would I go about cleaning the disc status from the array configuration utility?
noxchoGlobal Support CoordinatorCommented:
What options do you have in ACU for this unassigned drive?
What options are for Red X drive?
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BBraytonAuthor Commented:
the unassigned drive shows Create array for an option and More information.
The bad drive shows More information or View status alert
noxchoGlobal Support CoordinatorCommented:
Ok, then go the complex way - backup - reconfigure - restore.

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BBraytonAuthor Commented:
ok thanks will do
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