The drives must be the exact same size byte for byte, or larger, or the raid will not sync.
Raid sync does not have the capability to reduce a larger HD to a smaller HD, it simply sync's the drives.
You have to manually reduce the source drive raid size to equal to or less then the new drive, then sync.
If you attempt a manual size reduction, make sure you have a backup.
If the system tried to sync a larger source to a smaller destination drive and didn't give a warning then that might be considered a bug
in the raid sync.
Also take note:
If you have hda and add hdb and sync them and you want to move hdb to another machine (clone), then it is important to install that hdb
drive into the hdb position on the new hardware and add a new hda drive to the new hardware and sync them.
Of course you will have to change the bios to boot from hdb before the sync and change to hda after the sync.
Do not install the hdb drive into the new system into the hda position and a new drive in the hdb position.
Although it will work, things will get messed up and confusing down the road.
Raid maintains the drive position based on drive s/n in the raid config.
Same holds true for IDE, SCSI, SATA.
I'm sure one could modify/edit the raid config manually to correct the issue, however I haven't experimented with it as of this moment.
If someone has been able to accomplish it, would be a good addition to the wiki.
hth