SOLVED: Upgrade to 2.4.0 from 2.3.4-p1 Object Files not Found (Protectli Vault)



  • BACKGROUND

    I used the GUI to automatically upgrade from 2.3.4-p1 after which would not completely boot.  I connected KVM to my Protectli Vault and noticed there was some object files which were not found. (see attached image)

    SOLUTION

    I had to download and install from a USB stick.

    Steps to recover from 2.4.0-RELEASE upgrade from 2.3.4-p1
    BACKUP CONFIG

    format USB stick as FAT on macOS using Disk Utility app
    connect KVM to firewall
    reboot firewall
    login to firewall using root and password login
    insert USB stick into firewall
    create mount point: mkdir /mnt/usb
    mount_msdosfs /dev/da0s1 /mnt/usb
    cp /cf/conf/config.xml /mnt/usb/.
    unmount /mnt/usb

    CREATE PFSENSE USB STICK

    followed Install pfSense on Vault to download pfSense 2.4.0
    insert different USB stick into macOS
    open terminal
    sudo diskutil list # look for USB stick disk dev name
    sudo dd if={/path/name of image file} of=/dev/rdisk2 bs=1m # disk dev name from diskutil list command
    sudo diskutil eject /dev/disk2 # disk dev name from diskutil list command

    INSTALL PFSENSE

    soft power down firewall
    insert pfSense 2.4.0 USB stick
    power up firewall
    hit F11 to boot off USB stick
    stepped through menus to install pfSense 2.4.0

    RESTORE CONFIG

    soft power down firewall
    remove pfSense 2.4.0 USB stick
    insert first USB stick with config backup
    boot firewall
    enter shell
    follow BACKUP CONFIG steps above to mount USB stick
    cp /mnt/usb/config.xml /cf/conf/config.xml
    reboot

    REBOOT CLIENTS

    Because many of my clients are configured as DHCP, they all retained DHCP IP address assigned from the default pfSense config. I had to reboot both wired and wireless devices to retrieve reserved IP addresses I have in my configuration.