23.09.1 - pfsense-boot fails to upgrade

[jrey]

@pfBo @alethewizard

since @stephenw10 "unexpectedly small" isn't clearly defined, just for reference my virtual test machine (2.7.2 installed fine) is
40 532480 1 efi (260M)

but the production box (23.09) on a 2100
1 409600 1 efi (200M)

won't be upgrading my production netgate box until Monday, because upgrade policy for production says no upgrades on a Friday! But also have never had an issue with upgrades in the past at the 200 level.

Q. give me "unexpectedly small for 200 please"
A. what is too small?

[stephenw10]

Both those are expected sizes. If it was tiny, like <10M, that might be an issue but I don't think we've ever used that for amd64 installs.

We are still digging into this.

[alethewizard]

@stephenw10

Thank you.

I have always updated this VM from 2.4.5 to 2.7.1 without any issues.

[jrey]

@stephenw10
I figured you we're talking really small. but it is also good to have a reference points..

I honestly don't expect I'll have an issue at the 200 level on the 2100, never have.

I should also point out for reference that my 2.7.2 virtual is running on an Intel host.

[stephenw10]

Can we assume they are VMs configured as UEFI?

[alethewizard]

@jrey

Hi jrey.

What is your hypervisor?

Thanks.

[stephenw10]

@pfBo said in 23.09.1 - pfsense-boot fails to upgrade:

I'm getting this error during the upgrade process (see attached logfile). I wanted to paste it in but kept getting tagged as spam....

Upgrade_error_log.txt

I assume those are just excepts from the upgrade log? Do you have the full log available?

[alethewizard]

@stephenw10

Yes, EFI Virtual Machine on VMware ESXi.

[slu]

Same error for me:

https://forum.netgate.com/topic/184661/unable-to-upgrade-from-2-7-1-to-2-7-2-unmounting-boot-efi-done-failed

[jrey]

@alethewizard

I'm just running my test pfsense on a Virtual Box, hosted on a local intel MAC.

"Enable EFI" is selected and functioning.

[jimp]

What does this show for you (or anyone getting similar errors):

# df -hi /boot/efi/efi/boot/

[valerion]

@jimp said in 23.09.1 - pfsense-boot fails to upgrade:

What does this show for you (or anyone getting similar errors):

# df -hi /boot/efi/efi/boot/

[2.7.1-RELEASE][admin@<>]/root: df -hi /boot/efi/efi/boot/
Filesystem Size Used Avail Capacity iused ifree %iused Mounted on
zroot/ROOT/default 95G 1.1G 93G 1% 51k 196M 0% /

[2.7.1-RELEASE][admin@<>]/root: gpart show
=> 40 234454960 ada0 GPT (112G)
40 409600 1 efi (200M)
409640 1024 2 freebsd-boot (512K)
410664 984 - free - (492K)
411648 4194304 3 freebsd-swap (2.0G)
4605952 229847040 4 freebsd-zfs (110G)
234452992 2008 - free - (1.0M)

[alethewizard]

@valerion

Please read https://forum.netgate.com/topic/184661/unable-to-upgrade-from-2-7-1-to-2-7-2-unmounting-boot-efi-done-failed/15

[jimp]

The EFI partition isn't mounted there.

Do you have either /dev/msdosfs/EFISYS or /dev/gpt/EFISYS? If so, try this instead:

# mount_msdosfs /dev/msdosfs/EFISYS /boot/efi

Or

# mount_msdosfs /dev/gpt/EFISYS /boot/efi

Followed by the df -hi /boot/efi/efi/boot/ command.

[valerion]

@jimp said in 23.09.1 - pfsense-boot fails to upgrade:

The EFI partition isn't mounted there.

Do you have either /dev/msdosfs/EFISYS or /dev/gpt/EFISYS? If so, try this instead:

# mount_msdosfs /dev/msdosfs/EFISYS /boot/efi

Or

# mount_msdosfs /dev/gpt/EFISYS /boot/efi

Followed by the df -hi /boot/efi/efi/boot/ command.

I have the same results as others in the other thread.

Filesystem Size Used Avail Capacity iused ifree %iused Mounted on
/dev/msdosfs/EFISYS 779K 386K 393K 50% 3 509 1% /boot/efi

Guess there's a re-install in my future

[jimp]

Probably going to have to reinstall then in that case.

The old loader was quite a bit smaller. The newest version of the EFI loader is 643K which would barely fit in that partition, and since the installer tries to copy the new one over before deleting the old, it fails because there isn't enough room to hold both.

[jimp]

Reinstalling is the safest fix, but if you want to attempt to fix the partition manually, you can try the commands I posted in the other thread:

https://forum.netgate.com/post/1140955

But be sure to heed all the warnings.

[Arcao]

Same problem on my bare metal installation (pfSense installed in version 2.4.4, periodically updated to latest release, migrated to pfSense+).

@jimp Could you promote this issue as a known issue and arrange for it to be added into the release notes for other affected users?

[pfBo]

Hi all,

Sorry for the delay but here are my answers to (hopefully) all your questions and suggestions:

System info:
============
Netgate 5100 - Serial: NGXXXXXXXXXXXXXX - Netgate Device ID: XXXXXXXXXXXXXXXXXXXXXX

*** Welcome to Netgate pfSense Plus 23.09-RELEASE (amd64) on XXXXXXXXXX ***

gpart show:
===========
=>      40  15269808  mmcsd0  GPT  (7.3G)
        40    409600       1  efi  (200M)
    409640  14094335       2  freebsd-ufs  (6.7G)
  14503975         1          - free -  (512B)
  14503976    763904       3  freebsd-swap  (373M)
  15267880      1968          - free -  (984K)

df -hi /boot/efi/efi/boot/
df: /boot/efi/efi/boot/: No such file or directory

mount_msdosfs /dev/msdosfs/EFISYS /boot/efi

df -hi /boot/efi/efi/boot/
Filesystem             Size    Used   Avail Capacity iused ifree %iused  Mounted on
/dev/msdosfs/EFISYS    779K    644K    135K    83%       3   509    1%   /boot/efi

I don't mind reinstall if that's necessary but the system is about 600 miles away so it'll have to wait a few days until I get there.

Best regards,

Bo

[stephenw10]

Yes, you are affected by this because of that 800K EFI size. The system cannot update the EFI loader. It will require either reinstalling or expanding in place using the procedure in the linked post above.