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After applying the latest firmware, I received a notification:

DISK Error Notification
Disk(s) the error occurred:"Disk 2"
An error occurred and the 2th hard disk was removed from RAID array. 
Replace 2th hard drive.

At that point all data was still accessible.

So I replaced the disk and rebuilt the array. After 18 hours or so, the NAS started beeping and I receive:

DISK Error Notification
Disk(s) the error occurred:"Disk 3"
An error occurred in the 3th hard disk. 
Replace 3th hard drive.

I can still access the shares but only a fraction of the data is accessible. At that pint I shut down the Terastation to contemplate the next steps.

I assume:

- when I checked the replaced disk on my PC, there were no errors found all partitions seemed to be intact, I successfully formatted the disk and no read/write errors detected on a disk check.
- the issue seems rather data than hardware related
- disk 1,3 and 4 should still have all the data required to rebuild the RAID array

Is there a way I can re-add the "failed" drive 3 (a hardware failure seems very unlikely) or are there any other recovery options? I am a bit desperate as it seems like I have lost all my data.

well after a lot of research it looks as if I am not alone: a NAS which eats data after a Firmware update and does not offer for what I paid $700: resiliency

I have given up and removed the disks which are now working flawlessly in a QNAP NAS. I thought about flogging the Buffalo case on ebay but decided to spare the new owner the hassle and disposed of it as electronic waste as it's not fit for purpose.

That was my first and last Buffalo device, privately as well as professionally.