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Cannot add replacement drive (mdadm) not large enough to join array

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http://www.linuxquestions.org – using mdadm (version - v2.6.4 - 19th October 2007) on openfile filer kernel (2.6.29.6-0.24.smp.gcc3.4.x86.i686) I replaced a faulty 4tb hitachi drive (with another exact model) the error "not large enough to join array" steps: installed new drive, using parted, created label and partition identical to existing drives. used partprobe to sync part table, tried to add the disk with: mdadm --add /dev/md1 /dev/sdb1 The troubleshooting so far: blockdev --getsz got same results for all 3 hdparam -g got same results for all 3 I even tweaked the numbers in parted to give me a few b (HowTos)