ALRIGHT. So I returned the Quad Port Intel Gigabit NIC and am now using two dual port gigabit Intel NIC's with the new version of pfSense 2.4.0 . This appears to be running successfully now. I have tested it with the same load I placed against the previous build with the different NIC and it has not rebooted once yet. The Dual port NIC I got is the Intel PRO/1000 Py Dual Port Server Adapter. I will provide an update if the issue re-occurs but we appear to be running smoothly now.

@jimp: No, it is most likely too damaged to correct. Reinstall and use the "recover config.xml" option on the first screen of the installer to get your current config back. You'll be up and running in only a few moments. when i did the pkg-static update –f it all happend but i forgot to do  pkg-static upgrade –f  i cant remember if i saw that somewhere. After that was done i did the pfsense-upgrade and it all updated correctly. Didn't have to reinstall. only had to do the reinstall packaged from the Gui otherwise i would not access the addons via the Menu.

No. https://redmine.pfsense.org/issues/7029

Intel(R) Pentium(R) CPU 1403 @ 2.60GHz 2 CPUs: 1 package(s) x 2 core(s) 16304 MiB

@chpalmer: Plug its WAN port into your network. And…. Thanks a lot! it works! right now atleast.  ::)  :-[ How easy was that….... why was I breaking my head all day?... and why didn't tech support just tell me to, I asked specifically if I could not just do that.

Perfect! I had assumed that since I saw newer versions that they should show up via the update feature, but it makes sense that the functionality has been suspended till release. Thanks for the explanation.

Are all affected PCs on the same switch?  Could be a dead/unplugged switch and not pfSense at all…  Need more details!

And just to keep an old thread endlessly alive.. Upgraded 2.3.2 to 2.3.4_1 and it took just under 4hrs. I found this thread about 30 mins into the upgrade. I used the webGUI, the platform is nanobsd, the hardware is ancient AMD BE-2350. It did give me time to cobble together a newer system based on a MSI AM1M mobo, 4GB RAM, AMD 5350 cpu. I was able to restore the nanobsd config to the new 'full' platform. I'm always using HP NC365T quad port NIC cards - I've had great luck with them. You just have to remember the top port is igb3 and the bottom is igb0. This was the office router. I have a home one I plan to upgrade via console. We've rolled out 10-15 of these to our clients. Yes, there's some kind of bug in this process, but, a big THANKS! to the pfSense team and their continued commitment.

Yeah, your upgrade did not complete… And it will not ever complete most likely until re-attempted from console (option 13) and after killing most of the services except for dnsmasq (and sshd perhaps if required for upgrade). The nanoBSD installs on Alix boxes are no longer reasonably capable of upgrading due to limited RAM, sorry.

Solved, the install was successful. I believe my confusion with the ADI images was because i read documentation indicating they were for RCC-* devices. Thank you!