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[aasoror]

I think it's a bit safer to handle such a situation with RAID. I guess had the OP used RAID1

If you check the picture posted above, when check the "reconfigure with RAID" box, the NAS will reconfigure the new drive for RAID  AFTER is formats it. so even if you try to setup RAID, before doing that the NAS will go to the wrong drive (as in the OP case) and reformat it then try to RAID that with the new drive.

[fuelvolts]

I had the old drive in there and the new drive in a (formerly) empty slot.  As soon as it booted up, that menu popped up and said "your existing data will not be lost".  I clicked Next and it formatted my old hard drive.

This is a serious flaw and, of course, DLink is ignoring the situation.  No more DLink products for me ever and I will not recommend them to anyone who asks me for advice.

[mazy]

I am cognant of the problem and huge consequences here, and I agree that Dlink should do something about it. Implementing a few extra safeguards in the firmware can be simply done, as long as Dlink support gives a d$%^. But in the meanwhile, just to make sure we can formulate a "best practices" approach: Was the "new" drive you added totally brand new with no pre-existing partitions, files, etc on it?