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One of the Raid 5 disks was dying. I got replacement from vendor. It's the same disk. Has same size and everything. Checked with a disk utility has same number of head, sectors, etc. When I go to repair the volume with either disk management gui or disk part, it fails saying 'the size of the plex member is invalid'.

Only person who got past this had done it with 1 TB drives, and had initialized his disk as MBR, which used more space, so he initialized as GPT and it worked. These are 4 T disks, so I initialized as GPT. Nothing.

I've cleared the disk of it's boot sector and tried again like 5 times. Doesn't matter what I do.

Does anyone have a link or experience with this?

Thanks