I'm having an issue replacing a failed 500GB disk with another new one with the 
error that the disk is too small. The problem is that it isn't. Is there any 
help anyone can offer here?

I've tried adding it once set as a spare or seperate from the pool and with 
different formats and configs all to no avail. Is there a pre-requisite I am 
not fulfilling?

[b]bash-3.2# format[/b]
Searching for disks...done
AVAILABLE DISK SELECTIONS:
       0. c0d0 <DEFAULT cyl 993 alt 2 hd 255 sec 63>
          /p...@0,0/pci8086,2...@1c,3/pci-...@0/i...@0/c...@0,0
       1. c1d0 <WDC WD50-  WD-WCASY247370-0001-465.76GB>
          /p...@0,0/pci8086,2...@1e/pci-...@0/i...@0/c...@0,0
       2. c1d1 <SAMSUNG-S0MUJQSQA0223-0001-465.76GB>
          /p...@0,0/pci8086,2...@1e/pci-...@0/i...@0/c...@1,0
       3. c2d0 <WDC WD50-  WD-WCASY244407-0001-465.76GB>
          /p...@0,0/pci8086,2...@1e/pci-...@0/i...@1/c...@0,0
       4. c3d0 <SAMSUNG-S0MUJQSQA0224-0001-465.76GB>
          /p...@0,0/pci8086,2...@1e/pci-...@1/i...@0/c...@0,0
       5. c3d1 <SAMSUNG-S0VVJ1CP30560-0001-465.76GB>
          /p...@0,0/pci8086,2...@1e/pci-...@1/i...@0/c...@1,0
       6. c4d0 <SAMSUNG-S0VVJ1CP30539-0001-465.76GB>
          /p...@0,0/pci8086,2...@1e/pci-...@1/i...@1/c...@0,0
       7. c4d1 <SAMSUNG-S0VVJ1CP30561-0001-465.76GB>
          /p...@0,0/pci8086,2...@1e/pci-...@1/i...@1/c...@1,0
       8. c5t0d0 <ATA-SAMSUNG HD501LJ-0-10-465.76GB>
          /p...@0,0/pci1458,b...@1f,2/d...@0,0
       9. c5t1d0 <ATA-SAMSUNG HD501LJ-0-10-465.76GB>
          /p...@0,0/pci1458,b...@1f,2/d...@1,0
      10. c5t2d0 <ATA-SAMSUNG HD501LJ-0-10-465.76GB>
          /p...@0,0/pci1458,b...@1f,2/d...@2,0
      11. c5t3d0 <ATA-SAMSUNG HD501LJ-0-10-465.76GB>
          /p...@0,0/pci1458,b...@1f,2/d...@3,0
Specify disk (enter its number): 4
selecting c3d0
NO Alt slice
No defect list found
[disk formatted, no defect list found]
/dev/dsk/c3d0s0 is reserved as a hot spare for ZFS pool storage.  Please see 
zpool(1M).


FORMAT MENU:
        disk       - select a disk
        type       - select (define) a disk type
        partition  - select (define) a partition table
        current    - describe the current disk
        format     - format and analyze the disk
        fdisk      - run the fdisk program
        repair     - repair a defective sector
        show       - translate a disk address
        label      - write label to the disk
        analyze    - surface analysis
        defect     - defect list management
        backup     - search for backup labels
        verify     - read and display labels
        volname    - set 8-character volume name
        !<cmd>     - execute <cmd>, then return
        quit
[b]format> verify[/b]

Volume name = <        >
ascii name  = <SAMSUNG-S0MUJQSQA0224-0001-465.76GB>
bytes/sector    =  512
sectors = 976760063
accessible sectors = 976760030
Part      Tag    Flag     First Sector         Size         Last Sector
  0        usr    wm               256      465.75GB          976743646    
  1 unassigned    wm                 0           0               0    
  2 unassigned    wm                 0           0               0    
  3 unassigned    wm                 0           0               0    
  4 unassigned    wm                 0           0               0    
  5 unassigned    wm                 0           0               0    
  6 unassigned    wm                 0           0               0    
  8   reserved    wm         976743647        8.00MB          976760030    

[b]bash-3.2# zpool status[/b]
  pool: storage
 state: DEGRADED
status: One or more devices could not be opened.  Sufficient replicas exist for
        the pool to continue functioning in a degraded state.
action: Attach the missing device and online it using 'zpool online'.
   see: http://www.sun.com/msg/ZFS-8000-2Q
 scrub: none requested
config:

        NAME        STATE     READ WRITE CKSUM
        storage     DEGRADED     0     0     0
          raidz1    DEGRADED     0     0     0
            c2d0    ONLINE       0     0     0
            c2d1    UNAVAIL      0     0     0  cannot open
            c5t0d0  ONLINE       0     0     0
            c5t1d0  ONLINE       0     0     0
            c3d1    ONLINE       0     0     0
          raidz1    ONLINE       0     0     0
            c4d1    ONLINE       0     0     0
            c5t3d0  ONLINE       0     0     0
            c1d0    ONLINE       0     0     0
            c4d0    ONLINE       0     0     0
            c5t2d0  ONLINE       0     0     0
        spares
          c1d1      AVAIL   
          c3d0      AVAIL   

errors: No known data errors

[b]bash-3.2# zpool replace -f storage c2d1 c1d1[/b]
cannot replace c2d1 with c1d1: device is too small
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