Yes, you are right, it is an RAID 1 setup.
And yes, i think the raid is in sync (looking at /proc/mdstat).
Is there another way to check the sync?

Did you get my second mail to 521...@bugs.debian.org (2009-03-27)?
I dont know why it is not visible on 
http://bugs.debian.org/cgi-bin/bugreport.cgi?bug=521057.

Here are the essentials in brief:

================================
In the meantime i run several tests on my other Debian 5 Fileserver.
The tests were executed in the night, when no other aktion was made on the 
servers.
Four of five servers have problems while running fsck three times.

I put a raid with errors reported by fsck (Debian 5, configuration see my first 
mail)
in an Debian 4 Fileserver (configuration see below) and run "fsck.ext3 -n -f 
/dev/md0" ten times: no error was reported.

Here ist the Debian 4 configuration:

Package: e2fsprogs
Version: 1.39+1.40-WIP-2006.11.14+dfsg-2etch1

-- System Information:
Debian Release: 4.0
  APT prefers oldstable
  APT policy: (500, 'oldstable'), (500, 'stable')
Architecture: i386 (i686)
Shell:  /bin/sh linked to /bin/bash
Kernel: Linux 2.6.18-6-686
Locale: LANG=de_DE.UTF-8, LC_CTYPE=de_DE.UTF-8 (charmap=UTF-8)

Versions of packages e2fsprogs depends on:
ii  e2f 1.39+1.40-WIP-2006.11.14+dfsg-2etch1 ext2 filesystem libraries
ii  lib 1.39+1.40-WIP-2006.11.14+dfsg-2etch1 block device id library
ii  lib 2.3.6.ds1-13etch7                    GNU C Library: Shared libraries
ii  lib 1.39+1.40-WIP-2006.11.14+dfsg-2etch1 common error description library
ii  lib 1.39+1.40-WIP-2006.11.14+dfsg-2etch1 command-line interface parsing lib
ii  lib 1.39+1.40-WIP-2006.11.14+dfsg-2etch1 universally unique id library

e2fsprogs recommends no packages.

-- no debconf information
=====================================


Meanwhile i think it is an problem with a specific mainboard or bios (ECS 
P4vxad and Award Bios) and Debian 5.
In the following i do the test always 50 times.
When i put the RAID in a system with ECS P4vxad, Award Bios and Debian 5, in 
the majority of cases i got the errors.
Putting the same RAID in another system (identical hardware) and Debian 4, no 
errors occur.
Putting the same RAID in a system with different hardware neither with Debian 4 
nor with Debian 5 an error was reported.
So i switched my serves to a new hardware.
This solves the problem for me.
Maybe i test an bios-update for ECS P4vxad.

Manfred
 



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