Today I was able to troubleshoot my T740. End result is I am back on pfSense Plus version 23.09.1. I noticed the 2.7.2 update was offered in the WebUI. I confirmed the update install, BTX halted as usual. I decided to replace the boot drive from a SATA M.2 to a NVMe M.2 and remove the original eMMC card while I had the system open (eMMC has never been used for the OS install). My previous USB file edit worked and it booted into the installer right away. Since both BIOS and UEFI were broken previously I installed the OS for UEFI to test first. Install found my config.xml, applied the settings for ZFS to match the old drive, created the loader.conf.local file, and rebooted. No boot device found.... I forgot to enable UEFI in the BIOS so I enabled that and it booted into pfSense, I was excited so I immediately confirmed the update to 2.7.2 (before my packages were reinstalled automatically) and it installed and rebooted successfully. I then reapplied the Plus license my system was granted and rebooted again. All working now so far. I have only reinstalled acme and pfBlocker-NG and all seem well. I'll continue to see if I can get the loader.conf.local file to be applied/created during or right after setup, in a VM of course.