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Raid 5 Can't replace disk with bad blocks

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We have a server 2012r2 with 5 x 2Tb disks in Raid5

The raid 5 is a software raid using the Server o/s and dynamic disks

One of the disks has bad blocks and shows 'errors' both in Diskpart and Disk Management.

The s/n of the disk with errors has been identified using WMIC

If the disk is removed (also removed and replaced using the same or different controler) the volume is not created and there is no option to do so using either diskpart or Disk Management

When the disk is connected back into the raid Disk Management offers the opportunity to 'Repair Raid' and uses a spare disk same size purchased for the purpose and from the same batch. The repair seems to run and Resynchronise but does not complete. When checking which disks are changed the new disk is in place but the disk removed is not the one with errors and the raid shows failed redundancy.

The same happens using diskpart and commands

sel vol=* [* is the volume letter]

repair disk=# [# is the replacement disk number]

Previously for other raid 5 failures I hame removed the disk and repaired the raid with a replacement and there has been no problem.

Does anyone have any idea of how to replace the faulty disk?


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