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    Upgrade to 2.1.2: Stuck on 2.1

    Scheduled Pinned Locked Moved Problems Installing or Upgrading pfSense Software
    81 Posts 29 Posters 31.0k Views
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    • R
      robi
      last edited by

      Also a side note, I'm not on Alix, but on a Jetway JNF99 with 5 intel nics, Atom CPU and 4GB of RAM, i386 build. The new CF card will carry a 64-bit version this time.

      1 Reply Last reply Reply Quote 0
      • jimpJ
        jimp Rebel Alliance Developer Netgate
        last edited by

        If you're getting an "i/o error" or "device not configured", reboot and try again. At least for the "i/o error" it seems to lean more toward maybe a bad CF but it's still tough to say for sure.

        Also worth a try:

        sysctl kern.geom.debugflags=16
        fdisk -B -b /boot/boot0 ad0
        

        Remember: Upvote with the 👍 button for any user/post you find to be helpful, informative, or deserving of recognition!

        Need help fast? Netgate Global Support!

        Do not Chat/PM for help!

        1 Reply Last reply Reply Quote 0
        • M
          mjohnson
          last edited by

          I'm in the same boat with 40 plus devices scattered across 4 provinces. I actually haven't managed to get a single one to upgrade except the 3 in our local offices that I performed a clean install on, 2G and 4G, current versions 2.03 and 2.1 on all remotes attempting auto upgrade and manual firmware uploads. Not sure what to do, since I don't want to risk chopping them up and losing remote connectivity. I don't own a helicopter to get around that quickly  ;D

          All Alix boards. Errors in the upgrade log

          fdisk: invalid fdisk partition table found
          bsdlabel: /dev/ad0s3: no valid label found
          bsdlabel: /dev/ad0s3: no valid label found
          bsdlabel: /dev/ad0s3: no valid label found
          tar: Failed to set default locale
          tar: Failed to set default locale
          shutdown: [pid 24752]

          1 Reply Last reply Reply Quote 0
          • G
            gazoo
            last edited by

            I have same issue apparently. No answer. Here's my log:

            NanoBSD Firmware upgrade in progress...
            
            Installing /root/latest.tgz.
            SLICE         1
            OLDSLICE      2
            TOFLASH       ad0s1
            COMPLETE_PATH ad0s1a
            GLABEL_SLICE  pfSense0
            Sun Apr 13 02:37:42 EDT 2014
            
            total 8
            dr-xr-xr-x   7 root  wheel         512B Apr 12 15:03 .
            drwxr-xr-x  26 root  wheel         1.0k Apr 12 15:03 ..
            crw-r-----   1 root  operator    0,  56 Apr 12 15:03 ad0
            crw-r-----   1 root  operator    0,  57 Apr 12 15:03 ad0s1
            crw-r-----   1 root  operator    0,  60 Apr 12 15:03 ad0s1a
            crw-r-----   1 root  operator    0,  58 Apr 12 15:03 ad0s2
            crw-r-----   1 root  operator    0,  61 Apr 12 15:03 ad0s2a
            crw-r-----   1 root  operator    0,  59 Apr 12 15:03 ad0s3
            crw-------   1 root  operator    0,  28 Apr 12 15:03 ata
            crw-------   1 root  wheel       0,  11 Apr 13 01:29 bpf
            lrwxr-xr-x   1 root  wheel           3B Apr 12 15:03 bpf0 -> bpf
            crw-------   1 root  tty         0,   4 Apr 13 02:37 console
            crw-rw-rw-   1 root  wheel       0,  44 Apr 12 15:03 crypto
            crw-rw-rw-   1 root  wheel       0,  10 Apr 12 15:03 ctty
            crw-rw----   1 uucp  dialer      0,  35 Apr 12 15:03 cuau0
            crw-rw----   1 uucp  dialer      0,  36 Apr 12 15:03 cuau0.init
            crw-rw----   1 uucp  dialer      0,  37 Apr 12 15:03 cuau0.lock
            crw-rw----   1 uucp  dialer      0,  41 Apr 12 15:03 cuau1
            crw-rw----   1 uucp  dialer      0,  42 Apr 12 15:03 cuau1.init
            crw-rw----   1 uucp  dialer      0,  43 Apr 12 15:03 cuau1.lock
            crw-------   1 root  wheel       0,   5 Apr 12 15:03 devctl
            cr--------   1 root  wheel       0,  54 Apr 12 15:03 devstat
            dr-xr-xr-x   2 root  wheel         512B Apr 12 15:03 fd
            crw-------   1 root  wheel       0,  13 Apr 12 15:03 fido
            crw-r-----   1 root  operator    0,   3 Apr 12 15:03 geom.ctl
            crw-------   1 root  wheel       0,  23 Apr 12 15:03 io
            crw-------   1 root  wheel       0,   8 Apr 12 15:03 klog
            crw-r-----   1 root  kmem        0,  15 Apr 12 15:03 kmem
            dr-xr-xr-x   2 root  wheel         512B Apr 12 15:03 led
            crw-r-----   1 root  operator    0,  62 Apr 12 15:03 md0
            crw-r-----   1 root  operator    0,  66 Apr 12 15:03 md1
            crw-------   1 root  wheel       0,  47 Apr 12 15:03 mdctl
            crw-r-----   1 root  kmem        0,  14 Apr 12 15:03 mem
            crw-------   1 root  kmem        0,  16 Apr 12 15:03 nfslock
            crw-rw-rw-   1 root  wheel       0,  25 Apr 13 02:37 null
            crw-r--r--   1 root  wheel       0,  27 Apr 12 15:03 pci
            crw-rw----   1 root  proxy       0,  45 Apr 12 15:03 pf
            crw-rw-rw-   1 root  wheel       0,   9 Apr 12 15:03 ptmx
            crw-rw-rw-   1 root  wheel       0,   6 Apr 12 15:03 random
            crw-------   1 root  wheel       0,  24 Apr 12 15:03 speaker
            lrwxr-xr-x   1 root  wheel           4B Apr 12 15:03 stderr -> fd/2
            lrwxr-xr-x   1 root  wheel           4B Apr 12 15:03 stdin -> fd/0
            lrwxr-xr-x   1 root  wheel           4B Apr 12 15:03 stdout -> fd/1
            crw-------   1 root  wheel       0,  32 Apr 12 15:03 ttyu0
            crw-------   1 root  wheel       0,  33 Apr 12 15:03 ttyu0.init
            crw-------   1 root  wheel       0,  34 Apr 12 15:03 ttyu0.lock
            crw-------   1 root  wheel       0,  38 Apr 12 15:03 ttyu1
            crw-------   1 root  wheel       0,  39 Apr 12 15:03 ttyu1.init
            crw-------   1 root  wheel       0,  40 Apr 12 15:03 ttyu1.lock
            crw-------   1 uucp  dialer      0,  73 Apr 12 15:04 tun1
            dr-xr-xr-x   2 root  wheel         512B Apr 12 15:03 ufs
            dr-xr-xr-x   2 root  wheel         512B Apr 12 15:03 ufsid
            lrwxr-xr-x   1 root  wheel           9B Apr 12 15:03 ugen0.1 -> usb/0.1.0
            lrwxr-xr-x   1 root  wheel           9B Apr 12 15:03 ugen1.1 -> usb/1.1.0
            lrwxr-xr-x   1 root  wheel           6B Apr 12 15:03 urandom -> random
            dr-xr-xr-x   2 root  wheel         512B Apr 12 15:03 usb
            crw-r--r--   1 root  operator    0,  46 Apr 12 15:03 usbctl
            crw-------   1 root  operator    0,  55 Apr 12 15:03 xpt0
            crw-rw-rw-   1 root  wheel       0,  26 Apr 12 15:03 zero
            
            -rw-r--r--  1 root  wheel    76M Apr 13 02:34 /root/latest.tgz
            
            MD5 (/root/latest.tgz) = b914649dd6be90a461a99615c07882c3
            
            /dev/ufs/pfSense1 on / (ufs, local, noatime, synchronous)
            devfs on /dev (devfs, local)
            /dev/ufs/cf on /cf (ufs, local, noatime, synchronous)
            /dev/md0 on /tmp (ufs, local)
            /dev/md1 on /var (ufs, local)
            devfs on /var/dhcpd/dev (devfs, local)
            
            last pid: 52248;  load averages:  3.09,  1.78,  1.20  up 0+11:34:50    02:38:14
            67 processes:  7 running, 60 sleeping
            
            Mem: 92M Active, 50M Inact, 74M Wired, 6780K Cache, 33M Buf, 7052K Free
            Swap: 
            
              PID USERNAME  THR PRI NICE   SIZE    RES STATE    TIME   WCPU COMMAND
            92215 root        1  76    0 40308K 20156K accept   4:21  0.00% php
            86955 root        1  76    0 26484K 15784K accept   2:37  0.00% php
            41671 root        1  44    0  8004K  4984K kqread   1:04  0.00% lighttpd
            93099 root        1  76   20  3644K  1332K piperd   0:20  0.00% sh
              292 root        1  76   20  3352K  1112K kqread   0:15  0.00% check_reload_status
            45599 nobody      1  44    0  5512K  2316K select   0:12  0.00% dnsmasq
            31777 root        1  44    0  3264K  1208K select   0:12  0.00% apinger
            97171 root        1  44    0  3416K  1400K select   0:10  0.00% syslogd
            66552 root        1  44    0  7284K  5872K select   0:07  0.00% bsnmpd
            30425 root       21  44    0 21400K  3996K ucond    0:05  0.00% filterdns
            78170 root        1  64   20  6280K  6300K select   0:05  0.00% ntpd
            52603 dhcpd       1  44    0 11456K  7584K select   0:05  0.00% dhcpd
            25251 root        1  44    0  3264K   848K piperd   0:03  0.00% logger
            90659 proxy       1  64   20 10356K  5928K kqread   0:03  0.00% squid
            25151 root        1  44    0  5868K  1916K bpf      0:02  0.00% tcpdump
            61760 root        1  44    0  5952K  2324K kqread   0:01  0.00% lighttpd
            72531 root        1  64   20  5432K  3224K select   0:01  0.00% openvpn
            19617 root        1  44    0  5144K  1544K select   0:01  0.00% hostapd
            
            NanoBSD upgrade starting
            
            dd if=/dev/zero of=/dev/ad0s1 bs=1m count=1
            1+0 records in
            1+0 records out
            1048576 bytes transferred in 0.344171 secs (3046671 bytes/sec)
            
            /usr/bin/gzip -dc /root/latest.tgz | /bin/dd of=/dev/ad0s1 obs=64k
            3844449+0 records in
            30034+1 records out
            1968357888 bytes transferred in 394.695594 secs (4987028 bytes/sec)
            After upgrade fdisk/bsdlabel
            
            /sbin/fsck_ufs -y /dev/ad0s1a
            ** /dev/ad0s1a
            ** Last Mounted on /tmp/netgatemnt
            ** Phase 1 - Check Blocks and Sizes
            ** Phase 2 - Check Pathnames
            ** Phase 3 - Check Connectivity
            ** Phase 4 - Check Reference Counts
            ** Phase 5 - Check Cyl groups
            5506 files, 317470 used, 3462558 free (542 frags, 432752 blocks, 0.0% fragmentation)
            
            ***** FILE SYSTEM IS CLEAN *****
            
            /sbin/tunefs -L pfSense0 /dev/ad0s1a
            Checking for post_upgrade_command...
            Found post_upgrade_command, executing (pfSense0)...
            tar: Failed to set default locale
            Checking for /tmp/pfSense0/tmp/post_upgrade_command.php... 
            Running /tmp/pfSense0/tmp/post_upgrade_command.php pfSense0
            Adding serial port settings (/tmp/pfSense0)...
            Reading /tmp/pfSense0/boot/loader.conf...
            
            /dev/ufs/pfSense0 / ufs ro,sync,noatime 1 1
            /dev/ufs/cf /cf ufs ro,sync,noatime 1 1
            
            gpart set -a active -i 1 ad0
            gpart: table 'ad0' is corrupt: Operation not permitted
            
            /usr/sbin/boot0cfg -s 1 -v /dev/ad0
            #   flag     start chs   type       end chs       offset         size
            1   0x00      0:  1: 1   0xa5    751: 15:63           63      3854529
            2   0x80    752:  1: 1   0xa5    479: 15:63      3854655      3854529
            3   0x00    480:  0: 1   0xa5    581: 15:63      7709184       102816
            
            version=2.0  drive=0x80  mask=0x3  ticks=182  bell=# (0x23)
            options=packet,update,nosetdrv
            volume serial ID 9090-9090
            default_selection=F1 (Slice 1)
            Sun Apr 13 02:48:27 EDT 2014
            
            NanoBSD Firmware upgrade is complete.  Rebooting in 10 seconds.
            
            File list:
            /tmp/pfSense0
            /tmp/pfSense0/.snap
            /tmp/pfSense0/COPYRIGHT
            /tmp/pfSense0/bin
            /tmp/pfSense0/bin/cat
            /tmp/pfSense0/bin/chflags
            /tmp/pfSense0/bin/chmod
            /tmp/pfSense0/bin/cp
            /tmp/pfSense0/bin/csh
            /tmp/pfSense0/bin/tcsh
            /tmp/pfSense0/bin/date
            /tmp/pfSense0/bin/dd
            /tmp/pfSense0/bin/df
            /tmp/pfSense0/bin/domainname
            /tmp/pfSense0/bin/echo
            /tmp/pfSense0/bin/expr
            /tmp/pfSense0/bin/hostname
            /tmp/pfSense0/bin/kenv
            /tmp/pfSense0/bin/kill
            /tmp/pfSense0/bin/ln
            /tmp/pfSense0/bin/link
            .....a bunch more tmp files..
            Misc log:
            
            fdisk: invalid fdisk partition table found
            bsdlabel: /dev/ad0s3: no valid label found
            bsdlabel: /dev/ad0s3: no valid label found
            bsdlabel: /dev/ad0s3: no valid label found
            tar: Failed to set default locale
            tar: Failed to set default locale
            shutdown: [pid 82135]
            
            fdisk/bsdlabel log:
            
            Before upgrade fdisk/bsdlabel
            ******* Working on device /dev/ad0 *******
            parameters extracted from in-core disklabel are:
            cylinders=7745 heads=16 sectors/track=63 (1008 blks/cyl)
            
            Figures below won't work with BIOS for partitions not in cyl 1
            parameters to be used for BIOS calculations are:
            cylinders=7745 heads=16 sectors/track=63 (1008 blks/cyl)
            
            Media sector size is 512
            Warning: BIOS sector numbering starts with sector 1
            Information from DOS bootblock is:
            The data for partition 1 is:
            sysid 165 (0xa5),(FreeBSD/NetBSD/386BSD)
                start 63, size 3854529 (1882 Meg), flag 0
            	beg: cyl 0/ head 1/ sector 1;
            	end: cyl 751/ head 15/ sector 63
            The data for partition 2 is:
            sysid 165 (0xa5),(FreeBSD/NetBSD/386BSD)
                start 3854655, size 3854529 (1882 Meg), flag 80 (active)
            	beg: cyl 752/ head 1/ sector 1;
            	end: cyl 479/ head 15/ sector 63
            The data for partition 3 is:
            sysid 165 (0xa5),(FreeBSD/NetBSD/386BSD)
                start 7709184, size 102816 (50 Meg), flag 0
            	beg: cyl 480/ head 0/ sector 1;
            	end: cyl 581/ head 15/ sector 63
            The data for partition 4 is:
             <unused># /dev/ad0s1:
            type: unknown
            disk: amnesiac
            label: 
            flags:
            bytes/sector: 512
            sectors/track: 63
            tracks/cylinder: 16
            sectors/cylinder: 1008
            cylinders: 3813
            sectors/unit: 3844449
            rpm: 3600
            interleave: 1
            trackskew: 0
            cylinderskew: 0
            headswitch: 0		# milliseconds
            track-to-track seek: 0	# milliseconds
            drivedata: 0 
            
            8 partitions:
            #          size     offset    fstype   [fsize bsize bps/cpg]
              a:    3844433         16    unused        0     0   
              c:    3844449          0    unused        0     0     # "raw" part, don't edit
            # /dev/ad0s2:
            type: unknown
            disk: amnesiac
            label: 
            flags:
            bytes/sector: 512
            sectors/track: 63
            tracks/cylinder: 16
            sectors/cylinder: 1008
            cylinders: 3813
            sectors/unit: 3844449
            rpm: 3600
            interleave: 1
            trackskew: 0
            cylinderskew: 0
            headswitch: 0		# milliseconds
            track-to-track seek: 0	# milliseconds
            drivedata: 0 
            
            8 partitions:
            #          size     offset    fstype   [fsize bsize bps/cpg]
              a:    3844433         16    unused        0     0   
              c:    3844449          0    unused        0     0     # "raw" part, don't edit
            ---------------------------------------------------------------
            
            ******* Working on device /dev/ad0 *******
            parameters extracted from in-core disklabel are:
            cylinders=7745 heads=16 sectors/track=63 (1008 blks/cyl)
            
            Figures below won't work with BIOS for partitions not in cyl 1
            parameters to be used for BIOS calculations are:
            cylinders=7745 heads=16 sectors/track=63 (1008 blks/cyl)
            
            Media sector size is 512
            Warning: BIOS sector numbering starts with sector 1
            Information from DOS bootblock is:
            The data for partition 1 is:
            sysid 165 (0xa5),(FreeBSD/NetBSD/386BSD)
                start 63, size 3854529 (1882 Meg), flag 0
            	beg: cyl 0/ head 1/ sector 1;
            	end: cyl 751/ head 15/ sector 63
            The data for partition 2 is:
            sysid 165 (0xa5),(FreeBSD/NetBSD/386BSD)
                start 3854655, size 3854529 (1882 Meg), flag 80 (active)
            	beg: cyl 752/ head 1/ sector 1;
            	end: cyl 479/ head 15/ sector 63
            The data for partition 3 is:
            sysid 165 (0xa5),(FreeBSD/NetBSD/386BSD)
                start 7709184, size 102816 (50 Meg), flag 0
            	beg: cyl 480/ head 0/ sector 1;
            	end: cyl 581/ head 15/ sector 63
            The data for partition 4 is:
             <unused># /dev/ad0s1:
            type: unknown
            disk: amnesiac
            label: 
            flags:
            bytes/sector: 512
            sectors/track: 63
            tracks/cylinder: 16
            sectors/cylinder: 1008
            cylinders: 3813
            sectors/unit: 3844449
            rpm: 3600
            interleave: 1
            trackskew: 0
            cylinderskew: 0
            headswitch: 0		# milliseconds
            track-to-track seek: 0	# milliseconds
            drivedata: 0 
            
            8 partitions:
            #          size     offset    fstype   [fsize bsize bps/cpg]
              a:    3844433         16    unused        0     0   
              c:    3844449          0    unused        0     0     # "raw" part, don't edit
            # /dev/ad0s2:
            type: unknown
            disk: amnesiac
            label: 
            flags:
            bytes/sector: 512
            sectors/track: 63
            tracks/cylinder: 16
            sectors/cylinder: 1008
            cylinders: 3813
            sectors/unit: 3844449
            rpm: 3600
            interleave: 1
            trackskew: 0
            cylinderskew: 0
            headswitch: 0		# milliseconds
            track-to-track seek: 0	# milliseconds
            drivedata: 0 
            
            8 partitions:
            #          size     offset    fstype   [fsize bsize bps/cpg]
              a:    3844433         16    unused        0     0   
              c:    3844449          0    unused        0     0     # "raw" part, don't edit
            ---------------------------------------------------------------
            
            Final upgrade fdisk/bsdlabel
            ******* Working on device /dev/ad0 *******
            parameters extracted from in-core disklabel are:
            cylinders=7745 heads=16 sectors/track=63 (1008 blks/cyl)
            
            Figures below won't work with BIOS for partitions not in cyl 1
            parameters to be used for BIOS calculations are:
            cylinders=7745 heads=16 sectors/track=63 (1008 blks/cyl)
            
            Media sector size is 512
            Warning: BIOS sector numbering starts with sector 1
            Information from DOS bootblock is:
            The data for partition 1 is:
            sysid 165 (0xa5),(FreeBSD/NetBSD/386BSD)
                start 63, size 3854529 (1882 Meg), flag 0
            	beg: cyl 0/ head 1/ sector 1;
            	end: cyl 751/ head 15/ sector 63
            The data for partition 2 is:
            sysid 165 (0xa5),(FreeBSD/NetBSD/386BSD)
                start 3854655, size 3854529 (1882 Meg), flag 80 (active)
            	beg: cyl 752/ head 1/ sector 1;
            	end: cyl 479/ head 15/ sector 63
            The data for partition 3 is:
            sysid 165 (0xa5),(FreeBSD/NetBSD/386BSD)
                start 7709184, size 102816 (50 Meg), flag 0
            	beg: cyl 480/ head 0/ sector 1;
            	end: cyl 581/ head 15/ sector 63
            The data for partition 4 is:
             <unused># /dev/ad0s1:
            type: unknown
            disk: amnesiac
            label: 
            flags:
            bytes/sector: 512
            sectors/track: 63
            tracks/cylinder: 16
            sectors/cylinder: 1008
            cylinders: 3813
            sectors/unit: 3844449
            rpm: 3600
            interleave: 1
            trackskew: 0
            cylinderskew: 0
            headswitch: 0		# milliseconds
            track-to-track seek: 0	# milliseconds
            drivedata: 0 
            
            8 partitions:
            #          size     offset    fstype   [fsize bsize bps/cpg]
              a:    3844433         16    unused        0     0   
              c:    3844449          0    unused        0     0     # "raw" part, don't edit
            # /dev/ad0s2:
            type: unknown
            disk: amnesiac
            label: 
            flags:
            bytes/sector: 512
            sectors/track: 63
            tracks/cylinder: 16
            sectors/cylinder: 1008
            cylinders: 3813
            sectors/unit: 3844449
            rpm: 3600
            interleave: 1
            trackskew: 0
            cylinderskew: 0
            headswitch: 0		# milliseconds
            track-to-track seek: 0	# milliseconds
            drivedata: 0 
            
            8 partitions:
            #          size     offset    fstype   [fsize bsize bps/cpg]
              a:    3844433         16    unused        0     0   
              c:    3844449          0    unused        0     0     # "raw" part, don't edit
            ---------------------------------------------------------------</unused></unused></unused> 
            
            1 Reply Last reply Reply Quote 0
            • D
              Darkk
              last edited by

              @mjohnson:

              I'm in the same boat with 40 plus devices scattered across 4 provinces. I actually haven't managed to get a single one to upgrade except the 3 in our local offices that I performed a clean install on, 2G and 4G, current versions 2.03 and 2.1 on all remotes attempting auto upgrade and manual firmware uploads. Not sure what to do, since I don't want to risk chopping them up and losing remote connectivity. I don't own a helicopter to get around that quickly  ;D

              All Alix boards. Errors in the upgrade log

              fdisk: invalid fdisk partition table found
              bsdlabel: /dev/ad0s3: no valid label found
              bsdlabel: /dev/ad0s3: no valid label found
              bsdlabel: /dev/ad0s3: no valid label found
              tar: Failed to set default locale
              tar: Failed to set default locale
              shutdown: [pid 24752]

              I hear ya about all those remote devices and no time to travel there if there is a problem.  For me if there is a risk of breaking it at a remote site I would send them another firewall box and tell them to swap it when time permits.  This way the new firewall is working at the corporate office with the remote site's configuration file and should work fine when it reaches at the remote site.  Then have them send the old one back to redo for another site.

              I know it's a PITA.  Might be good for critical sites that can't go down for any period of time.  Hopefully soon we can get these upgrade issues sorted out.

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              • jimpJ
                jimp Rebel Alliance Developer Netgate
                last edited by

                I have a faulty image in my hands now, hopefully I can track down a solution soon.

                Current theory is that it was actually corrupt before the latest update and it just started to show it now, but once I have more time to experiment with the broken CF image I'll know for sure.

                I'm certain we can come up with a fix, but it might be something scary like doing a DD of a good partition table to the start of the disk. Not something I'd generally recommend however in theory all NanoBSD images of the same size should have the same partition layout so it may be safe.

                In the meantime I'd like to find out if everyone involved here had 4GB NanoBSD images, or both 2GB and 4GB, or even more.

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                • M
                  me too
                  last edited by

                  Both 4GB CF for me.

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                  • M
                    mjohnson
                    last edited by

                    2 and 4GB for me.

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                    • R
                      RCS-Michael
                      last edited by

                      Jim,

                      I have both 2G and 4G nanobsd images displaying this problem.

                      Michael

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                      • jimpJ
                        jimp Rebel Alliance Developer Netgate
                        last edited by

                        For those of you that have an issue, show me the output of:

                        fdisk -p /dev/ad0
                        

                        And note if it's 2gb or 4gb.

                        If you have a working system of the same size to compare against, show the output from it also.

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                        • M
                          mkomar
                          last edited by

                          Not working: 2GB

                          /dev/ad0

                          g c3875 h16 s63
                          p 1 0xa5 63 1902033
                          a 1
                          p 2 0xa5 1902159 1902033
                          p 3 0xa5 3804192 102816

                          Working: 4GB

                          /dev/ad0

                          g c7751 h16 s63
                          p 1 0xa5 63 3844449
                          p 2 0xa5 3844575 3844449
                          a 2
                          p 3 0xa5 7689024 102816

                          Not Working: 2GB

                          /dev/ad0

                          g c3875 h16 s63
                          p 1 0xa5 63 1902033
                          p 2 0xa5 1902159 1902033
                          a 2
                          p 3 0xa5 3804192 102816

                          Working: 2GB

                          /dev/ad0

                          g c3897 h16 s63
                          p 1 0xa5 63 1902033
                          a 1
                          p 2 0xa5 1902159 1902033
                          p 3 0xa5 3804192 102816

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                          • jimpJ
                            jimp Rebel Alliance Developer Netgate
                            last edited by

                            Those last two are interesting in that they're nearly identical and one works and the other doesn't. I expect some variation as we have, over time, slightly shrunk the NanoBSD slice sizes, but that is a bit curious.

                            The .img file I read from the CF with the "corrupt" table appears to be OK, despite the CF showing a damaged table. So I'm left to wonder if there may be some other CF-related factor at play.

                            The following commands could be dangerous so if you choose to attempt them, proceed with extreme caution. I tested these on my own ALIX with a good MBR and it survived, but there are no guarantees. You need only try one of these methods unless it doesn't help, then proceed to the next one.

                            Method #1: Rewrite the MBR+Partition table with dd

                            sysctl kern.geom.debugflags=16
                            dd if=/dev/ad0 of=/tmp/mbr_part_bkup.img bs=512 count=1
                            dd of=/dev/ad0 if=/tmp/mbr_part_bkup.img bs=512 count=1
                            
                            

                            Method #2: Have fdisk reset the partition table:

                            sysctl kern.geom.debugflags=16
                            fdisk -p /dev/ad0 > /tmp/fdisk_bkup.txt
                            fdisk -if /tmp/fdisk_bkup.txt /dev/ad0
                            
                            

                            Method #3: Take a "working" fdisk output and rewrite using it. I can't stress enough that you must make sure the partition boundaries line up, don't grab the fdisk output from a differently sized card:

                            
                            # Get the "fdisk -p" output from a similar but working CF, save it in /tmp/fdisk_bkup.txt
                            sysctl kern.geom.debugflags=16
                            fdisk -if /tmp/fdisk_bkup.txt /dev/ad0
                            
                            

                            After any of those, chances are that no commands will work to reboot the unit, so either pull the power or run the following to force a panic+reboot:

                            sysctl debug.debugger_on_panic=0
                            sysctl debug.kdb.panic=1
                            

                            After that has completed, try the upgrade once again.

                            Obviously that isn't something you'd want to try on a remote unit.

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                            • M
                              mkomar
                              last edited by

                              All of mine are in remote locations and in production. Can't risk taking them down.

                              I'll be swapping them out with upgraded (Software) replacements in the next week or so.

                              Is there value in trying these fixes after that?

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                              • jimpJ
                                jimp Rebel Alliance Developer Netgate
                                last edited by

                                @mkomar:

                                All of mine are in remote locations and in production. Can't risk taking them down.

                                I'll be swapping them out with upgraded (Software) replacements in the next week or so.

                                Is there value in trying these fixes after that?

                                It would still help to know if any of the above methods would correct the faulty partition table, so that others can benefit from the knowledge.

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                                • M
                                  mkomar
                                  last edited by

                                  I should have a couple of those units on hand next week. I'll give it a shot and report back once I've done so.

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                                  • M
                                    mkomar
                                    last edited by

                                    JimP - Should have my hands on one or two of the malfunctioning units in the next few days. I'd be happy to try the various fixes you have proposed, and/or if it would be of more value, I'd be happy to either get you serial access to one or both of them and/or get either CF card(s) and/or dd img dumps out to you.

                                    Would any of the options work better than others as far as getting a 'known good' fix out there?

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                                    • jimpJ
                                      jimp Rebel Alliance Developer Netgate
                                      last edited by

                                      From my post a few entries up ( https://forum.pfsense.org/index.php?topic=75069.msg413219#msg413219 ) – I listed them in order of preference (and likely destructive potential!)

                                      So try them in that order, method #1, then #2, then #3 only if both 1 and 2 fail.

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                                      Do not Chat/PM for help!

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                                      • M
                                        mkomar
                                        last edited by

                                        [2.1-RELEASE][root@pfsense]/root(1): sysctl kern.geom.debugflags=16
                                        kern.geom.debugflags: 0 -> 16
                                        [2.1-RELEASE][root@pfsense]/root(2): d if=/dev/ad0 of=/tmp/mbr_part_bkup.img bs=512 count=1
                                        dd of=/dev/ad0 if=/tmp/mbr_part_bkup.img bs=512 count=1dd if=/dev/ad0 of=/tmp/mbr_part_bkup.img bs=512 count=1
                                        1+0 records in
                                        1+0 records out
                                        512 bytes transferred in 0.000771 secs (664033 bytes/sec)
                                        [2.1-RELEASE][root@pfsense]/root(3): dd of=/dev/ad0 if=/tmp/mbr_part_bkup.img bs=512 count=1
                                        1+0 records in
                                        GEOM_PART: integrity check failed (ad0, MBR)

                                        512 bytes transferred in 0.024720 secs (20712 bGEOM: ad0s1: media size does not match label.
                                        ytes/sec)
                                        GEOM: ad0s2: media size does not match label.
                                        [2.1-RELEASE][root@pfsense]/root(4):

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                                        • P
                                          pmiller
                                          last edited by

                                          I also have the problem in this post and have been following it closely.  I am particularly interested in an in-place fix since I don't have an extra CF card or reader to re-flash.

                                          mkomar - in the third line of your post shouldn't there be 2 d's instead of one for the 'dd' command?  Maybe a copy/paste error?

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                                          • M
                                            MattMeyer
                                            last edited by

                                            Adding my experience to the thread.  I am also having the same issue.  I am using a SanDisk Extreme 4 GB CF.  This is the output for fdisk -p /dev/ad0:

                                            /dev/ad0

                                            g c7751 h16 s63
                                            p 1 0xa5 63 3861585
                                            a 1
                                            p 2 0xa5 3861711 3861585
                                            p 3 0xa5 7723296 102816

                                            i have tried recreating the MBR using both the dd method and the fdisk method.  Both did not help with a successful upgrade.  I do not have a working device that I can copy the MBR so option #3 is out.

                                            Additionally, trying to change the boot slice does not "stick".

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