Hot swapping out a failed SATA /dev/sda drive worked fine, but when I went to swap in a new drive, it wasn't recognized:

[root@fs-2 ~]# tail -18 /var/log/messages
May 5 16:54:35 fs-2 kernel: ata1: exception Emask 0x10 SAct 0x0 SErr 0x50000 action 0xe frozen
May 5 16:54:35 fs-2 kernel: ata1: SError: { PHYRdyChg CommWake }
May 5 16:54:40 fs-2 kernel: ata1: link is slow to respond, please be patient (ready=0)
May 5 16:54:45 fs-2 kernel: ata1: device not ready (errno=-16), forcing hardreset
May 5 16:54:45 fs-2 kernel: ata1: soft resetting link
May 5 16:54:50 fs-2 kernel: ata1: link is slow to respond, please be patient (ready=0)
May 5 16:54:55 fs-2 kernel: ata1: SRST failed (errno=-16)
May 5 16:54:55 fs-2 kernel: ata1: soft resetting link
May 5 16:55:00 fs-2 kernel: ata1: link is slow to respond, please be patient (ready=0)
May 5 16:55:05 fs-2 kernel: ata1: SRST failed (errno=-16)
May 5 16:55:05 fs-2 kernel: ata1: soft resetting link
May 5 16:55:10 fs-2 kernel: ata1: link is slow to respond, please be patient (ready=0)
May 5 16:55:40 fs-2 kernel: ata1: SRST failed (errno=-16)
May 5 16:55:40 fs-2 kernel: ata1: limiting SATA link speed to 1.5 Gbps
May 5 16:55:40 fs-2 kernel: ata1: soft resetting link
May 5 16:55:45 fs-2 kernel: ata1: SRST failed (errno=-16)
May 5 16:55:45 fs-2 kernel: ata1: reset failed, giving up
May 5 16:55:45 fs-2 kernel: ata1: EH complete

I tried a couple things to make the server find the new /dev/sda, such as rescan-scsi-bus.sh but they didn't work:

[root@fs-2 ~]# echo "---" > /sys/class/scsi_host/host0/scan
-bash: echo: write error: Invalid argument
[root@fs-2 ~]#
[root@fs-2 ~]# /root/rescan-scsi-bus.sh -l
[snip]
0 new device(s) found.
0 device(s) removed.
[root@fs-2 ~]#
[root@fs-2 ~]# ls /dev/sda
ls: /dev/sda: No such file or directory

I ended up rebooting the server. /dev/sda was recognized, I fixed the software RAID, and everything is fine now. But for next time, how can I make Linux recognize a new SATA drive I have hot swapped in without rebooting?

The operating system in question is RHEL5.3:

[root@fs-2 ~]# cat /etc/redhat-release
Red Hat Enterprise Linux Server release 5.3 (Tikanga)

The hard drive is a Seagate Barracuda ES.2 SATA 3.0-Gb/s 500-GB, model ST3500320NS.

Here is the lscpi output:

[root@fs-2 ~]# lspci
00:00.0 RAM memory: nVidia Corporation MCP55 Memory Controller (rev a2)
00:01.0 ISA bridge: nVidia Corporation MCP55 LPC Bridge (rev a3)
00:01.1 SMBus: nVidia Corporation MCP55 SMBus (rev a3)
00:02.0 USB Controller: nVidia Corporation MCP55 USB Controller (rev a1)
00:02.1 USB Controller: nVidia Corporation MCP55 USB Controller (rev a2)
00:04.0 IDE interface: nVidia Corporation MCP55 IDE (rev a1)
00:05.0 IDE interface: nVidia Corporation MCP55 SATA Controller (rev a3)
00:05.1 IDE interface: nVidia Corporation MCP55 SATA Controller (rev a3)
00:05.2 IDE interface: nVidia Corporation MCP55 SATA Controller (rev a3)
00:06.0 PCI bridge: nVidia Corporation MCP55 PCI bridge (rev a2)
00:08.0 Bridge: nVidia Corporation MCP55 Ethernet (rev a3)
00:09.0 Bridge: nVidia Corporation MCP55 Ethernet (rev a3)
00:0a.0 PCI bridge: nVidia Corporation MCP55 PCI Express bridge (rev a3)
00:0b.0 PCI bridge: nVidia Corporation MCP55 PCI Express bridge (rev a3)
00:0c.0 PCI bridge: nVidia Corporation MCP55 PCI Express bridge (rev a3)
00:0d.0 PCI bridge: nVidia Corporation MCP55 PCI Express bridge (rev a3)
00:0e.0 PCI bridge: nVidia Corporation MCP55 PCI Express bridge (rev a3)
00:0f.0 PCI bridge: nVidia Corporation MCP55 PCI Express bridge (rev a3)
00:18.0 Host bridge: Advanced Micro Devices [AMD] K8 [Athlon64/Opteron] HyperTransport Technology Configuration
00:18.1 Host bridge: Advanced Micro Devices [AMD] K8 [Athlon64/Opteron] Address Map
00:18.2 Host bridge: Advanced Micro Devices [AMD] K8 [Athlon64/Opteron] DRAM Controller
00:18.3 Host bridge: Advanced Micro Devices [AMD] K8 [Athlon64/Opteron] Miscellaneous Control
00:19.0 Host bridge: Advanced Micro Devices [AMD] K8 [Athlon64/Opteron] HyperTransport Technology Configuration
00:19.1 Host bridge: Advanced Micro Devices [AMD] K8 [Athlon64/Opteron] Address Map
00:19.2 Host bridge: Advanced Micro Devices [AMD] K8 [Athlon64/Opteron] DRAM Controller
00:19.3 Host bridge: Advanced Micro Devices [AMD] K8 [Athlon64/Opteron] Miscellaneous Control
03:00.0 VGA compatible controller: Matrox Graphics, Inc. MGA G200e [Pilot] ServerEngines (SEP1) (rev 02)
04:00.0 PCI bridge: NEC Corporation uPD720400 PCI Express - PCI/PCI-X Bridge (rev 06)
04:00.1 PCI bridge: NEC Corporation uPD720400 PCI Express - PCI/PCI-X Bridge (rev 06)

Update: In perhaps a dozen cases, we've been forced to reboot servers because hot swap hasn't "just worked." Thanks for the answers to look more into the SATA controller. I've included the lspci output for the problematic system above (hostname: fs-2). I could still use some help understanding what exactly isn't supported hardware-wise in terms of hot swap for that system. Please let me know what other output besides lspci might be useful.

The good news is that hot swap "just worked" today on one of our servers (hostname: www-1), which is very rare for us. Here is the lspci output:

[root@www-1 ~]# lspci
00:00.0 RAM memory: nVidia Corporation MCP55 Memory Controller (rev a2)
00:01.0 ISA bridge: nVidia Corporation MCP55 LPC Bridge (rev a3)
00:01.1 SMBus: nVidia Corporation MCP55 SMBus (rev a3)
00:02.0 USB Controller: nVidia Corporation MCP55 USB Controller (rev a1)
00:02.1 USB Controller: nVidia Corporation MCP55 USB Controller (rev a2)
00:04.0 IDE interface: nVidia Corporation MCP55 IDE (rev a1)
00:05.0 IDE interface: nVidia Corporation MCP55 SATA Controller (rev a3)
00:05.1 IDE interface: nVidia Corporation MCP55 SATA Controller (rev a3)
00:05.2 IDE interface: nVidia Corporation MCP55 SATA Controller (rev a3)
00:06.0 PCI bridge: nVidia Corporation MCP55 PCI bridge (rev a2)
00:08.0 Bridge: nVidia Corporation MCP55 Ethernet (rev a3)
00:09.0 Bridge: nVidia Corporation MCP55 Ethernet (rev a3)
00:0b.0 PCI bridge: nVidia Corporation MCP55 PCI Express bridge (rev a3)
00:0c.0 PCI bridge: nVidia Corporation MCP55 PCI Express bridge (rev a3)
00:0f.0 PCI bridge: nVidia Corporation MCP55 PCI Express bridge (rev a3)
00:18.0 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] HyperTransport Configuration
00:18.1 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] Address Map
00:18.2 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] DRAM Controller
00:18.3 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] Miscellaneous Control
00:18.4 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] Link Control
00:19.0 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] HyperTransport Configuration
00:19.1 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] Address Map
00:19.2 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] DRAM Controller
00:19.3 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] Miscellaneous Control
00:19.4 Host bridge: Advanced Micro Devices [AMD] K10 [Opteron, Athlon64, Sempron] Link Control
03:00.0 VGA compatible controller: Matrox Graphics, Inc. MGA G200e [Pilot] ServerEngines (SEP1) (rev 02)
04:00.0 PCI bridge: NEC Corporation uPD720400 PCI Express - PCI/PCI-X Bridge (rev 06)
04:00.1 PCI bridge: NEC Corporation uPD720400 PCI Express - PCI/PCI-X Bridge (rev 06)
09:00.0 SCSI storage controller: LSI Logic / Symbios Logic SAS1064ET PCI-Express Fusion-MPT SAS (rev 04)