Hello everyone,
I am currently facing an issue with the expansion of the vdev in my pool called ‘truenas’.
It consists out of 4x8TB HDDs and I want to put another two of the same size in there.
When trying to expand it, I am met with the below error:
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middlewared.service_exception.CallError: [EFAULT] Could not create a partition of 8001563172352 bytes on disk sdd because the disk is too small. If you are replacing a disk in a pool, please ensure that the new disk is not smaller than the disk being replaced. Could not create partition 1 from 2048 to 15628055117 Could not change partition 1's type code to BF01! Error encountered; not saving changes.(Tried via:
Storage > Unused Disk > Add to Pool
Storage > Topology > Manage Devices > Expand
Storage > Truenas (my pool) > Expand)
zpool status:
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truenas_admin@truenas[~]$ sudo zpool status [sudo] password for truenas_admin: pool: boot-pool state: ONLINE scan: scrub repaired 0B in 00:00:04 with 0 errors on Wed Oct 29 03:45:05 2025 config: NAME STATE READ WRITE CKSUM boot-pool ONLINE 0 0 0 nvme0n1p3 ONLINE 0 0 0 errors: No known data errors pool: truenas state: ONLINE config: NAME STATE READ WRITE CKSUM truenas ONLINE 0 0 0 raidz1-0 ONLINE 0 0 0 f9bf2b20-7233-4a52-83d7-0ba172f1a5e0 ONLINE 0 0 0 86364bc7-6d0e-4efb-8940-211bbdb5e48a ONLINE 0 0 0 8005d765-eab5-497a-9ae8-01a796f1f6fa ONLINE 0 0 0 0cc56694-cd67-4ea8-9ba4-468e1d6c246b ONLINE 0 0 0 errors: No known data errors
lsblk (/sdd and /sde are the affected drives, same models are already in the pool)
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truenas_admin@truenas[~]$ lsblk -bo NAME,MODEL,ROTA,PTTYPE,TYPE,START,SIZE,PARTTYPENAME,PARTUUID NAME MODEL ROTA PTTYPE TYPE START SIZE PARTTYPENAME PARTUUID sda WDC WD80EFZX-68UW8N0 1 gpt disk 8001563222016 └─sda1 1 gpt part 64 8001563172352 Linux filesystem 86364bc7-6d0e-4efb-8940-211bbdb5e48a sdb ST8000DM004-2U9188 1 gpt disk 8001563222016 └─sdb1 1 gpt part 64 8001563172352 Linux filesystem f9bf2b20-7233-4a52-83d7-0ba172f1a5e0 sdc WDC WD80EFZX-68UW8N0 1 gpt disk 8001563222016 └─sdc1 1 gpt part 64 8001563172352 Linux filesystem 8005d765-eab5-497a-9ae8-01a796f1f6fa sdd WDC WD80EFZX-68UW8N0 1 disk 8001563222016 sde WDC WD80EMAZ-00WJTA0 1 gpt disk 8001563222016 sdf WDC WD80EMAZ-00WJTA0 1 gpt disk 8001563222016 └─sdf1 1 gpt part 64 8001563172352 Linux filesystem 0cc56694-cd67-4ea8-9ba4-468e1d6c246b zd0 0 gpt disk 42949672960 nvme0n1 ORICO 0 gpt disk 128035676160 ├─nvme0n1p1 0 gpt part 4096 1048576 BIOS boot e917ae59-0257-4943-a909-0f8636d20b76 ├─nvme0n1p2 0 gpt part 6144 536870912 EFI System 9fe5f40b-07d8-4038-9a5e-df3edaf65c5e └─nvme0n1p3 0 gpt part 1054720 127495642624 Solaris /usr & Apple ZFS a02564a5-f6a0-45a1-9224-45b91b36e3ae
Output of parted -l from one working drive in the pool, and the two that can’t be added:
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Model: ATA WDC WD80EFZX-68U (scsi) Disk /dev/sdc: 8002GB Sector size (logical/physical): 512B/4096B Partition Table: gpt Disk Flags: Number Start End Size File system Name Flags 1 32.8kB 8002GB 8002GB zfs Error: /dev/sdd: unrecognised disk label Model: ATA WDC WD80EFZX-68U (scsi) Disk /dev/sdd: 8002GB Sector size (logical/physical): 512B/4096B Partition Table: unknown Disk Flags: Model: ATA WDC WD80EMAZ-00W (scsi) Disk /dev/sde: 8002GB Sector size (logical/physical): 512B/4096B Partition Table: gpt Disk Flags: Number Start End Size File system Name Flags
lspci
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truenas_admin@truenas[~]$ lspci 00:00.0 Host bridge: Intel Corporation Device 461c 00:02.0 VGA compatible controller: Intel Corporation Alder Lake-N [UHD Graphics] 00:0a.0 Signal processing controller: Intel Corporation Platform Monitoring Technology (rev 01) 00:14.0 USB controller: Intel Corporation Alder Lake-N PCH USB 3.2 xHCI Host Controller 00:14.2 RAM memory: Intel Corporation Alder Lake-N PCH Shared SRAM 00:15.0 Serial bus controller: Intel Corporation Device 54e8 00:16.0 Communication controller: Intel Corporation Alder Lake-N PCH HECI Controller 00:17.0 SATA controller: Intel Corporation Alder Lake-N SATA AHCI Controller 00:1c.0 PCI bridge: Intel Corporation Alder Lake-N PCI Express Root Port 00:1c.3 PCI bridge: Intel Corporation Device 54bb 00:1c.6 PCI bridge: Intel Corporation Alder Lake-N PCI Express Root Port 00:1d.0 PCI bridge: Intel Corporation Alder Lake-N PCI Express Root Port 00:1f.0 ISA bridge: Intel Corporation Alder Lake-N PCH eSPI Controller 00:1f.3 Audio device: Intel Corporation Alder Lake-N PCH High Definition Audio Controller 00:1f.4 SMBus: Intel Corporation Alder Lake-N SMBus 00:1f.5 Serial bus controller: Intel Corporation Alder Lake-N SPI (flash) Controller 02:00.0 SATA controller: ASMedia Technology Inc. ASM1166 Serial ATA Controller (rev 02) 03:00.0 Ethernet controller: Realtek Semiconductor Co., Ltd. RTL8111/8168/8411 PCI Express Gigabit Ethernet Controller (rev 15) 04:00.0 Non-Volatile memory controller: MAXIO Technology (Hangzhou) Ltd. NVMe SSD Controller MAP1202 (rev 01)
storcli
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truenas_admin@truenas[~]$ sudo storcli show all CLI Version = 007.2807.0000.0000 Dec 22, 2023 Operating system = Linux 6.12.15-production+truenas Status Code = 0 Status = Success Description = None Number of Controllers = 0 Host Name = truenas Operating System = Linux 6.12.15-production+truenas
OS Version: 25.04.2.5
What have I done so far?:
- I have tried adding a partition table, a partition, setting start, end etc but they just get removed / blank formatted again when trying to add them to the pool (latest attempt was to add /sdd, that’s why its’s not showing anything.
- I’ve tried to replace a drive from the pool but it gives the same error.
- I’ve tried to export / import the pool
- I’ve did a complete power cycle of the NAS
What do I need help with?
Is there any way to further troubleshoot this?
Happy with any suggestions but if possible I would like to avoid copying the data to another drive, deleting the pool and re-creating it with all 6 drives, only to re-copy it into the new pool!
