This should have worked...
Is the firmware on the raid card at the newest level?
"The size of the 4 discs are 33.92 Gig Brand New(not refurbished) size is 34.43 Gig."
This should not be an issue.
If the replacement disk is the EXACT make and model as the original array set, and the replacement disk has the same firmware revision, and the raid card firmware is up to date....
Possible (most likely) a second disk in the array has errors, which is not being failed by the adapter, is causing the rebuild to fail. Have you run the Dell diags, also have you run a consistency check previously. It is VERY difficult to find such a drive, standard SCSI disk testing software( with each array disk connected to a standard SCSI adapter, often passes array disks which fail on a raid adapter). If another disk in the array has "offlined" previously, this is the likely culprit.
Rarely, a different model disk is not compatible with original array disks, but this is very rare
Backup
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