I agree with you on that, I've just tested all my drives and they are in perfect working order.
FYI, after creating a RAID 5 Volume and transferring a ton of data to it, is when I get the dregraded message, maybe it's hitting a 2TB treashold or something like that. I read somewhere that a workaround for this was to remove and reinsert the problem drive while the unit is still running but carn't find the post anywhere now.
I think I'll be happy with creating 4 single volumes, I can not see the point of having RAID now if I have everything else backed up elsewhere