SG-1100 Upgrade 23.09.1 to 24.03_1 failure

manzato

I've upgraded the pkg tool (via pkg upgrade pkg) and giving it another try to the upgrade.

manzato

Managed to get a core dump when running the upgrade...

[176/180] Fetching expat-2.5.0.pkg: . done
[177/180] Fetching php83-sysvsem-8.3.1.pkg: . done
[178/180] Fetching php83-pecl-rrd-2.0.3.pkg: . done
[179/180] Fetching py311-libzfs-1.1.2023020700.pkg: ...... done
[180/180] Fetching sshguard-2.4.3_2,1.pkg: .......... done
Checking integrity...Bus error (core dumped)

stephenw10

Hmm, anything in the system logs when either of those fail?

Check for coredumps in /root. What actually dumped?

manzato

@stephenw10 I didn't find any core dumps... And actually the upgrade of pkg was "downgraded" after a reboot. I am able to write to the filesystem (tried writing to most of them).

Without the upgraded pkg, it isn't core dumping anymore, but still the upgrade fails and I can't find any smoking gun... no logs, nothing suspicious.

Any pointers / ideas?

stephenw10

Try rebooting and then running the upgrade at the console without logging into the webgui so the maximum resources are available.

Otherwise you can always install 24.03 clean and restore the config.

manzato

@stephenw10 Tried the clean boot without the GUI, same issue. Where can I download the fresh install of 24?

stephenw10

Get the Net Installer as shown here:
https://docs.netgate.com/pfsense/en/latest/solutions/sg-1100/reinstall-pfsense.html

manzato

@stephenw10

I ran a fresh installation and got another failure:

I think I can assume there is a HW error on my device at this point.

juanzelli

@manzato Just checking to see if you tried a different USB stick too

stephenw10

Hmm, that does seem like it could be a storage issue.

manzato

@stephenw10 is there anything I can try to confirm it? Is it serviceable in any way? Or is it going to the trash can?

stephenw10

Well I would try several times at least. And I would try using several USB sticks.

When it fails like that you can drop to the shell and check what the exact errors are.

I would start by just running: dmesg

If it's a drive issue you will see a bunch of errors show there.