Replace faulty disk in linux md

Replacing a faulty drive in an mdadm managed RAID array.

Use 'mdadm –manage /dev/mdX -r /dev/sdF' to remove the drive that was marked as faulty from the array.
Power down and replace the drive with a good drive.
Power up and set the partition table on the new drive to match those of the other drives in the array. Here we used 'sfdisk -d /dev/sdN | sfdisk /dev/sdF'.
Add the proper partition on the new drive into the array, 'mdadm –manage /dev/mdX -a /dev/sdN2'
Sit back and wait for the recovery to happen. The system will be a bit slow but usable.

Ref:

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