@rvjr:
Hi MrJonny,
that happened to me too on the SG4860:
I had used only two gige ports, port1 for WAN, and port2 for 4 LANs as tagged VLANs. I didn't use the port2 untagged. I setup traffic shaping rules for the VLANs, but for an experiment I added a shaping rule on the untagged port2 interface, and then the pfSense box was completely dead. Booting resulted in it to hang on "Starting dns resolver…" on the serial console, and booting without lan cables attached caused a kernel panic. I could only restore a very old config because I had no recent backup (which will never happen to me again ;-)), and I don't know about other recovery methods. Unfortunately I didn't have time to consult the forum or any official support because I had to get everything running as fast as possible again.
Good to hear its not just me, hopefully someone will look in to this.
I restored my config, by going in to single user mode.
Remounted the filesystem as read/write. Went to "/cf/conf/" deleted "conf.xml" and went in to "/cf/conf/backups/" copied one of the most recents backups to "/cf/conf/config.xml" not the most recent because I'm guessing that one would have the change we made to traffic shaper. Rebooted and working fine again