So 10 years and a few employers ago, we had a case of a few "haunted" server chassis. Hard drives would fail on these chassis very frequently, and when a fresh drive was swapped in, it would take many days to rebuild the RAID, if it ever rebuilt at all.
Putting the RAID set in a new machine, it would rebuild fine. But in the original machine, we swapped out the raid controller, CPU's, even the whole motherboard, and the RAID sets still would not rebuild.
Long story short, each of these "haunted" servers had a bad fan that was causing a lot of vibration within the chassis - enough physical vibration happening that the hard drives were essentially rendered inoperable.
The moral of the story is to make sure you have good vibration dampening on your fans, and to use the sensors monitoring to alert you if the fans are going bad. (Even this is not perfect, since sometimes the fan gets off-kilter but is still happily spinning at 10K RPM. The first thing we did if we got an alert for a disk failure was to replace the fans and attempt a RAID rebuild before touching the "bad" disk)
This wasn't a Sun E450 was it? We had one (of a "matched" pair) that was "haunted" as well. Drives died, Sun replaced drives. Drives died again. Sun replaced SCSI controller and drives. Drives died again. Sun replaced motherboard, SCSI controller, memory, and drives. Drives died again, and we make the (at the time) scary move to Pentium III app servers, which were inexpensive enough to triple up compared to SPARC, but even better, drives didn't die.
We swapped out the E450s for 440s for Oracle when we moved to InterNAP, and all seemed to be well.
Hearing your story, I wouldn't be surprised if we had just enough/wrong vibration in the case to make it go Tacoma Narrows on us.
These haunted servers were actually supermicro barebones chassis.
It has been a (long) while since I have seen the inside of an e450 but iirc there were a bunch of fans in trays in there. So it is certainly possible that the vibration did bad things. I still carry one of the e450 era keys on my keychain as a momento.
Putting the RAID set in a new machine, it would rebuild fine. But in the original machine, we swapped out the raid controller, CPU's, even the whole motherboard, and the RAID sets still would not rebuild.
Long story short, each of these "haunted" servers had a bad fan that was causing a lot of vibration within the chassis - enough physical vibration happening that the hard drives were essentially rendered inoperable.
The moral of the story is to make sure you have good vibration dampening on your fans, and to use the sensors monitoring to alert you if the fans are going bad. (Even this is not perfect, since sometimes the fan gets off-kilter but is still happily spinning at 10K RPM. The first thing we did if we got an alert for a disk failure was to replace the fans and attempt a RAID rebuild before touching the "bad" disk)