Testing the drive was more straightforward than testing the board. After the badblocks run, my suspicions were with the board rather than the drive.

Answering your other post, there's no seperate "signal cable" to the drive, but we've tried three different IDE drive ribbons with no change in behavior.

My question was whether or not there's a well-known procedure for replacing a degraded drive. 3Ware's support is less than clear on this point. If we're missing something obvious, it would be good to know about it.

We've got another 3Ware board (with its own set of issues), but suspect that swapping it would require an array archive, delete, rebuild, restore, which is pretty much a full day operation. For this box, that means weekend work.