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09/02/2007 13:27:32 13 W L01 | File System Check : Excessive bad blks I=15502072 (Skipping)
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This is one reason I run SpinRite on all new HD's.
It's looks like the HD you replaced was not the one, since it failed resysce. I did not want a replacement drive installed. Now re image all hds (maybe just the one that was replaced) and remove another hd. If it reports a broken raid5 you will have to reimage all drives to original state. I would not put in the replacement drive. I want it to run in degrade mode. This way your are only dealing with one variable at a time. Beside when you get to drive 1 it must be identical, a over size drive will not work.