Problems with Proliant ML350 G4 RAIID Rebuild

[dmundrickrockyview.ab.c]

We are currently having issues with rebuilding a RAID 5 array on a Proliant ML350 G4. The controller is a Smart Array 641, and the operating system is NetWare 6.5.

One of our three drives disconnected from the Logical Drive. Alas, I was not there when it happened and an overzealous user rebooted the server a few times as it was allegedly unresponsive. I tried removing the drive and replacing it. The RAID 5 rebuild started, but then failed after about 7%. Several retries showed the same behavior. I ordered a replacement drive, updated the server BIOS to the latest version, updated the Smart Array 641 firmware to latest version, installed new drive...same result. The Logical Drive status shows as Rebuilding, all physical status lights are working...then suddenly it stops rebuilding and NetWare shows a message that it is Queued for Rebuild.

I ran diags on the Array and everything appears okay.

Any ideas?