Public bug reported:

Binary package hint: initramfs-tools

Using Kubuntu Feisty Fawn 7.04, i386, release version. Sometimes Ubuntu
fails to bring up non-root md arrays, which causes non-root filesystems
to be unmountable and interrupts the init process. /dev/md0, which
houses the root file system, is brought up fine.

Hardware: Abit AB9 Pro motherboard, uses Intel P965 chipset with ICH8R
southbridge. Hard disks connected to the SATA ports offered by the
chipset, using AHCI mode. Hard disks are 3 identical 250 GiB Seagate
Barracudas, connected to SATA ports 1-3.

HDD:s are partitioned as follows (exact fdisk -l output available if
necessary):

/dev/sdb1 128 MiB 0x83, /boot (ext3)
/dev/sdb2 40 GiB 0x07, /media/sdb2 (ntfs, Win XP system partition)
/dev/sdb3 210 GiB 0x0f (Win95 Extended (LBA))
/dev/sdb5 512 MiB 0x82 (swap)
/dev/sdb6 14 GiB 0xfd (part of RAID5 array /dev/md0)
/dev/sdb7 45 GiB 0xfd (part of RAID5 array /dev/md1)
/dev/sdb8 45 GiB 0xfd (part of RAID5 array /dev/md2)
/dev/sdb9 45 GiB 0xfd (part of RAID5 array /dev/md3)
/dev/sdb10 45 GiB 0xfd (part of RAID5 array /dev/md4)

/dev/sda and /dev/sdc have identical partition tables, except for the
partiton type of partition 2 (W95 LBA on sda, Linux on sdc). And of
course, only /dev/sdb1 is mounted as /boot. The raid arrays have been
created using Edgy's alternate installer (side note: feisty's installer
appears to be buggy, it gives an "invalid argument" when handling RAID
arrays - will write a separate bug report on this).

/dev/md0 houses the root filesystem (ext3). /dev/md[1-4] are physical
volumes for LVM volume group mainvg, which contains lv's homelv (/home,
ext3), varlv (/var, ext3), usrlv (/usr, ext3) and mmedia (/multimedia,
xfs).

As stated above, the bug occurs during boot. Sometimes arrays md[1-4]
fail to assemble (lots of "assembling array mdx -- fail!" errors). This
doesn't yet interrupt the boot process, but now as the LVM vg is missing
all its physical volumes, mainvg doesn't come up, homelv, usrlv, varlv
and mmedialv are unavailable, fsck notes this as a lot of broken
filesystems and drops to root shell. On root shell, cat /proc/mdstat
shows only the md0 array, md[1-4] can be brought up using mdadm
--assemble.

There's a fix detailed in e.g.
http://www.meta.net.nz/~daniel/blog/2007/04/12/feisty-fawn-and-software-
raid/ - in short, boot passing break=mount as option, add
/sbin/udevsettle --timeout 10 as the last line of /usr/share/initramfs-
tools/scripts/init-premount/udev and rebuild initrd 'update-initramfs -u
-k all'. This fixed the issue.

I'm filing this as a separate bug report, since it seems to be the
policy that all SATA and/or RAID related bugs should be filed
separately, and the (working) fix is different than the ones proposed in
bug 103177.

** Affects: initramfs-tools (Ubuntu)
     Importance: Undecided
         Status: Unconfirmed

-- 
Software RAID sometimes fails to assemble arrays on boot
https://bugs.launchpad.net/bugs/114170
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