Recently I needed to add 2 more 1tb drives to my current RAID5 x3 1TB setup. This was all done with a hotswap cage and no downtime. I will show you how I added the first one in this example enclosure(252) slot(2). Clear it

MegaCli -pdclear -start -physdrv '[252:2]' -a0

Set state to (Unconfigured Good)

MegaCli -pdmakegood -physdrv '[252:2]' -a0

Add to current logical volume

MegaCli -ldrecon -start -add -physdrv '[252:2]' -l0 -a0

Check Progress sigh…

MegaCli -ldrecon -showprog -l0 -a0

Prepare for a pretty long wait if you have a large array.

Reconstruction on VD #0 (target id #0) Completed 43% in 501 Minutes.

and this is for a 1.8TB with and additional 1TB drive being added to the array.

/dev/mapper/vg0-lvol0 1.8T 1.6G 1.8T 1% /media/pub

Yeah!