Let me help you with this.
I would like to know more about your configuration and the system behavior. When having a RAID 5 configuration you must identify the damaged HDD and replace it.
Once the HDD is replaced you must select the option Rebuild and the process should start without any problem.
The drive is not faulty. This occurred as a result of flashing a separate host adapter. It is a Rocket 640L and after years of no updates they finally had some firmware on their site, two versions. A quick check on the internet noted it fixed a 'resume from sleep' issue.
It was flashed. It may be designed only for MacBook Pros, they failed to name the file or notate it in the changelog/readme. The card freezes the system when the adapter's BIOS should initialize.
The drive geometry of the first drive in a four-disk array was altered during this process. A suspicion is that the separate adapter's firmware somehow affected it. Windows may have written, the lockups did cause a CMOS reset. The system wouldn't progress to loading Windows while the card was installed.
A 1TB drive is offered as a rebuild to another disk option and that is difficult to understand. The problem is likely rebuild cannot be completed without a disc of equal or greater size. The question is now, "will a zero-write correct 48-bit geometry, and if not, how can that be accomplished." I intend the attempt in the near future. Someone knowledgeable on this subject would be appreciated. Screenshots of the drives' HWiNFO geometry were added to the link.
48 bit geometry was a Standard Created on 2003 so by now all HDD should support this geometry. It is possible to rebuild the HDD when having another drive with the same or higher capacity.
The problem was corrected with a zero write. Intel's RST should indicate that drives need to meet a size requirement. There is no purpose in offering drives smaller. It is poor programming.