I would boot to the latest Firmware CD and update all firmware. Sounds like it could be the RAID controller. Have you bounced it? Also, does it try to rebuild (like the arrow and disk lights flash)?
Yes, could be that the new disk has the latest firmware which may be causing the issue. Also may be worth replacing the disk with the OS not loaded (swapping the disk with the ACU loaded through SmartStart).
Also check the HP logs to see if anything strange is logged
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