I believe this is an fdisk issue.  But I don't think any
of the fdisk engineers hang out on this forum.

You might try partitioning the disk on another OS.
  -- richard

Antonius wrote:
> I'll attach 2 files of output from 2 disks:
> 
> c4d0 is a current member of the zpool that is a "sibling" (as in a member of 
> the same batch a couple of serial number increments different) of the faulted 
> disk to replace and currently running without issue
> 
> and c3d0 is a new disk I got back from as a replacement for a failed disk 
> that's obviously different. it appears the EFI label needs fixing. I just 
> can't get it to stick with any combination of commands I've tried.
> 
> eg removing and resetting all partitions with fdisk -e
> and trying to recreate with geometry as per the existing pool members even 
> after trying to dd the first section of all partitions:
> 
> bash-3.2# fdisk -A 238:0:0:1:0:254:63:1023:1:976773167 c3d0
> fdisk: EFI partitions must encompass the entire disk
> (input numsect: 976773167 - avail: 976760063)
> 
> 
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