In a multi-disk setup, one sometimes needs to replace a drive. If one has a hot-swap bay, this is surprisingly easy, but before actually pulling the drive out, one MUST tell Linux that one is about to do so:
# echo 1 > /sys/block/sdX/device/delete
You can then pull the drive out and replace it with a new one. Note, though, that the new drive will generally get a new device name (e.g., /dev/sdZ), until the next reboot.
Now, say that you want the drive to have identical partitions to another drive (say, sdY) in your system, then you simple copy the partition tables:
# sfdisk -d /dev/sdY | sfdisk /dev/sdZ
This can all be done without ever rebooting the system :-)
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Of course, if the drive in question was part of a RAID array (say, /dev/mdA), then one would first issue:
# mdadm /dev/mdA --fail /dev/sdXn
# mdadm /dev/mdA --remove /dev/sdXn
Then, one would replace the drive as noted in the post, after which one would add the partition on the new drive back into the array:
# mdadm /dev/mdA --add /dev/sdZn
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