[case 16733639] ReadyNAS Pro Pioneer 6 stuck in sync (6%)

I'm having problems booting / syncing after the upgrade to 4.2.19

I've been a happy ReadNAS user since Nov of 2010.

Im using a Netgear ReadyNas Pro Pioneer Edition 6-bay High Performance NAS Drive with 6 drives
ReadyNAS Pro Pioneer Edition [X-RAID2]
RAIDiator 4.2.19
Memory: 1024 MB [4-5-5-15 DDR2]
VolumeC: Online, X-RAID2, 6 disks, 97% of 7399 GB used
RAID Level X-RAID2, 6 disks (with dual redundancy)
Resync 5% complete, Time to finish 764 hr 55 min, Speed 502 KB/sec

6x Seagate 2TB - Seagate ST2000DL003-9VT166 [1863 GB] (on hardware compatibilty list)

The machine is archiving large files and small files -- rsync'ing two remote machine, OS release ISO's, timemachine backups for 3 macs, mkv videos, zip/gz'd/RAR'd stuff, ~10 years of JPG photos, my iTunes library, podcasts, etc.

The system boots ok, goes thru a FS check just fine.

However, it then tries to go about a resync. Initially it predicts it'll take about 4-6 hours. During which time I can access the drive, frontview, raider, etc.

But then it hits 5% or 6% sync and suddenly it's predicting 128 or 700+ hours to finish. Worse, at this point, I can't ssh to the device any longer, frontview access takes forever and/or fails entirely. RAIDair cant even see it. And if I happen to have had a ssh connection open I get a "cp" I/O errors or hangs.

I've turned off all the time machines and network automounts (even turned off the computers)

Is it possible that the combination of my 97% capacity and the "factory reset" of my settings after the 4.2.19 upgrade (enabling journaling) is causing me to run into issues?

I tried mount a 1.5TB USB drive to my mac and copy (via terminal "cp" commands) off some files to give it some "breathing room", but I only got about 3G off before it hung again. Maybe I can try and hook the external USB drive up directly the readynas and try that.

I've read:

Perf Turning ( was tuned, but seems to have been reset after my upgrade )
http://www.readynas.com/?p=310

and
Slow Sync / Copy / Hang ( seems similar? )
viewtopic.php?f=21&t=35069


I'm going to try the boot/reset-button sequence and try the disk scans.

http://www.readynas.com/kb/faq/boot/how ... _boot_menu

Is there anything further I can do to debug / diagnose the issue? Right now I cant even tell if I have a bad disk that I can replace, a series of bad blocks in a file, faulty hardware, disks w/not enough space for a resync, etc.

I'll try opening a case file.

SMART+ dump: (they all look similar I think)

Model: 	ST2000DL003-9VT166
Serial: 	5YD1PS70
Firmware: 	CC32

SMART Attribute
	
Spin Up Time	0
Start Stop Count	13
Reallocated Sector Count	0
Power On Hours	4681
Spin Retry Count	0
Power Cycle Count	13
Reported Uncorrect	0
High Fly Writes	1
Airflow Temperature Cel	37
G-Sense Error Rate	0
Power-Off Retract Count	11
Load Cycle Count	13
Temperature Celsius	37
Current Pending Sector	0
Offline Uncorrectable	0
UDMA CRC Error Count	0
Head Flying Hours	112687056949833
	
ATA Error Count	0