PfSense doesn't boot
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If you upgrade your systems with the upgradefiles that we provide you shouldn't lose your config. it will be upgraded on the fly. However making a backup of your config and having a media to reinstall from is recommended though for me all upgrades have been always flawless.
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The problem is that pfSense isn't booting :\ so I can't make the upgrade in the GUI, and I can't make the backup either :(
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Boot the newest livecd. If you are lucky and your hdd is not corrupt it will mount the hdd and use it's config.xml. Then download it from the webgui before attempting a reinstall.
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I'm using pfSense trough vmware
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You can even do this with vmware. Just mount the livecd iso as cd in your vm and boot from it.
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pfSense has booted with the LiveCD.
What do I need to do to save the old configs now? -
In the webgui grab the config from the following page: diagnostics>backup/restore
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But won't that config be the default one from the livecd?
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Not if it found a config on the old broken harddrive installation and used that one. The livecd checks multiple locations on bootup for a config.xml and uses that one if available. It only will use the default config if it doesn't find one somewhere. Why discuss, just try it and see if it is your "old" config. Takes less time than discussing this here.
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But won't that config be the default one from the livecd?
When I wrote this reply, I already tried it, but it didn't boot with my settings, is it possible do mount the HD manually and get the .xml?
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Then it's probably just broken and beyond rescue :-\