Won't boot after 25.11 upgrade

ghulands

My machine isn't booting. The upgrade log with most likely relevant piece.

Architecture: amd64
Boot Devices: /dev/nda0
 Boot Method: uefi
  Filesystem: zfs
    Platform: unknown hardware


Updating boot code...

/usr/local/sbin/../libexec/install-boot.sh -b auto -d /tmp/be_mount.AQdE -f zfs -s gpt -u nda0
gpart bootcode -b /tmp/be_mount.AQdE/boot/pmbr -p /tmp/be_mount.AQdE/boot/gptzfsboot -i 2 nda0
partcode written to nda0p2
bootcode written to nda0
ESP /dev/nda0p1 mounted on /tmp/stand-test.4SViIb
0KB space remaining on ESP: renaming old bootx64.efi file /efi/boot/bootx64.efi /efi/boot/bootx64-old.efi
Copying loader.efi to /EFI/freebsd on ESP
cp: /tmp/be_mount.AQdE/boot/loader.efi: Input/output error
Existing UEFI FreeBSD boot entry found: not creating a new one
Copying bootx64.efi to /efi/boot on ESP
cp: /tmp/be_mount.AQdE/boot/loader.efi: Argument list too long
Unmounting and cleaning up temporary mount point
Finished updating ESP

The machine is in the attic so i will need to get a ladder in the morning to hook up a monitor to see what is going on. I seem to recall a similar boot issue reported for 25.07.

SteveITS

@ghulands is it an old install? The EFI partition might be too small. In which case a reinstall would be a way to fix that.

ghulands

@SteveITS How old is old? I think I originally built the system about 7 years ago.

chpalmer

@ghulands Yeah.. that's about old..

I had to reinstall from scratch for a 10 year old install..

ghulands

@chpalmer Thanks. I do a reinstall tomorrow

chpalmer

@ghulands Yep.. just grab an update of your config file before you start the process no matter how old your last config save was.. Always good to be sure. ;)

ghulands

@chpalmer Turned out the SSD was throwing SMART errors that the BIOS prevented boot up. EFI was hosed as well which I assumed would happen, but renaming the bootx64-old.efi to bootx64.efi didn't help. I also tried to just launch the bootx64.efi from the efi shell, but it threw an error.

I've ordered a couple of new SSD's that I'll put in a mirror. They should be here tomorrow.

ghulands

I got the new SSD's and installed a fresh build of pfSense. I was able to rescue the config.xml off the failing ssd by importing the pool on my linux box and copying it back to pfsense.

Back in business!