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

[elvisimprsntr]

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.