From mboxrd@z Thu Jan  1 00:00:00 1970
From: "Dan Williams" <dan.j.williams@intel.com>
Subject: Re: Raid 1, new disk can't be added after replacing faulty disk
Date: Mon, 7 Jan 2008 12:11:58 -0700
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To: Radu Rendec <radu.rendec@ines.ro>
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On Jan 7, 2008 6:44 AM, Radu Rendec <radu.rendec@ines.ro> wrote:
> I'm experiencing trouble when trying to add a new disk to a raid 1 array
> after having replaced a faulty disk.
>
[..]
> # mdadm --version
> mdadm - v2.6.2 - 21st May 2007
>
[..]
> However, this happens with both mdadm 2.6.2 and 2.6.4. I downgraded to
> 2.5.4 and it works like a charm.

Looks like you are running into the issue described here:
http://marc.info/?l=linux-raid&m=119892098129022&w=2