Disk array raid 5 rebuilding failed

[LinpusBruce]

Hi,

I have a raid5 disk array problem on ProLiant DL160 G5. Few days ago, one of the disk in the array went down, so I replace it with a new one, and the controller start to rebuild it. But everytime when the process in about 67% it will stop. The ACU(Array Configuration Utility) will show the array is Ready to Recovery. After I reboot the system, it will show the rebuild is aborted when the initialize and ask me enable the auto recovery. After enter ACU, it starts rebuilding once again from 0%

I have 4 hard disk in the array. Each one of them is 250 GB. The one I replace is bay4, but I replace it with a 1TB hard disk. I run ACU with CD-ROM.

Did anyone know what's wrong when recovery? Thanks for your help.