Daniel, thank you much for taking the time to examine the logs. The drives were purchased together in same shipment 4 months ago. I ran Dell Online Diagnostics disk self test on the drives. PD03 failed the dst test, but passed the quick test. The other 2 drives in array passed the dst test.
I ordered more Dell drives. I'll try replacing drive again in a few days and let you know results.
Here's my plan:
1) Run consistency check
2) Force drive offline via OMSA
3) Insert new disk and verify build results
4) Run consistency check