Grub crc error after decompressing linux

grub

I have a debian with a raid1 on it.
Both HDDs have bootable flags and grub setup in MBR.
If I only start up with sda, linux boots.
If I only start up with sdb, grub shows up and says 

Decompressing Linux...
crc error
-- System halted

I have reinstalled grub a few times now but still nothing.
It goes like this:
/dev/md0 contains /dev/sda1 /dev/sdb1
find /boot/grub/stage1 shows (hd0,0) (hd0,1)
The line that boots Linux shows:
root (hd0,0)
kernel /vmlinuz-2.6.26-1-686
initrd /initrd.img-2.6.26-1-686

This kind of renders my "redundant" array useless.
Any clues?

update:
just to mention, these are 2 different HDDs, sda is 320gb and sdb is 400gb. Both are WD and both have exactly the same partitions, cloned using sfdisk.

Best Answer

If you built the raid correctly and it fully synced then chances are high that you have some bad sectors on sdb.

What does the output of 

cat /proc/mdstat

say about the device ?

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