You could try to do the PCB swap on the drive that isn't working long enough to rebuild the array, copy every thing off and then switch the PCB back and RMA the bad drive(s). I've done the PCB swap 4 times myself. Once on a friends TiVo.


If you can't get the raid to rebuild and you can get your hands on two or three spare drives you can use R-Studio (If you have a windows PC) to make an image of each drive. R-Studio then has an option to create a raid array from the images and restore the data.