If you hot swap a disk in a cluster, even using the same geometry, the new disk may appear to be on-line but it does NOT function properly.
When the Cluster service locates a disk by its signature, it use the physical disk number to control it, never rechecking the signature.
The proper way to hot swap a disk in a cluster, without restarting, is:
1. Hot swap the disk.
2. Remove the disk using Device Manager.
3. In Disk Management, run Rescan Disks to detect the new drive.