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I've finally got it working. The SSD that was installed was reporting that everything was fine through all the testing that I did on it. Bad sector tests, smart tests, ect. I got a new drive and installed it and reinstalled opnsense and everything is working fine now.

I setup a 2nd router so I can mess around with OPNsense without knocking my family off the internet.

It seems the boot failure is not related to installing packages/updates on the system. After a fresh install I go though reboot the system a twice from the WebUI every time on the 2nd reboot the system no longer sees the boot drive.

I don't see anything that sticks out in the SMART information. I'm thinking there is a bug with the package installer screen that is breaking the boot partition.

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smartctl 7.2 2020-12-30 r5155 [FreeBSD 12.2-STABLE amd64] (local build)
Copyright (C) 2002-20, Bruce Allen, Christian Franke, www.smartmontools.org

=== START OF INFORMATION SECTION ===
Device Model:     SAMSUNG MZNTD256HAGL-000L9
Serial Number:    S1ETNYAF609268
LU WWN Device Id: 5 002538 500000000
Firmware Version: DXT22L6Q
User Capacity:    256,060,514,304 bytes [256 GB]
Sector Size:      512 bytes logical/physical
Rotation Rate:    Solid State Device
TRIM Command:     Available, deterministic, zeroed
Device is:        Not in smartctl database [for details use: -P showall]
ATA Version is:   ACS-2, ATA8-ACS T13/1699-D revision 4c
SATA Version is:  SATA 3.1, 6.0 Gb/s (current: 6.0 Gb/s)
Local Time is:    Tue Jun 22 08:43:40 2021 CDT
SMART support is: Available - device has SMART capability.
SMART support is: Enabled
AAM feature is:   Unavailable
APM feature is:   Unavailable
Rd look-ahead is: Enabled
Write cache is:   Enabled
DSN feature is:   Unavailable
ATA Security is:  Disabled, frozen [SEC2]
Wt Cache Reorder: Enabled

=== START OF READ SMART DATA SECTION ===
SMART overall-health self-assessment test result: PASSED

General SMART Values:
Offline data collection status:  (0x00) Offline data collection activity
was never started.
Auto Offline Data Collection: Disabled.
Self-test execution status:      (   0) The previous self-test routine completed
without error or no self-test has ever
been run.
Total time to complete Offline
data collection: (53956) seconds.
Offline data collection
capabilities: (0x5b) SMART execute Offline immediate.
Auto Offline data collection on/off support.
Suspend Offline collection upon new
command.
Offline surface scan supported.
Self-test supported.
No Conveyance Self-test supported.
Selective Self-test supported.
SMART capabilities:            (0x0003) Saves SMART data before entering
power-saving mode.
Supports SMART auto save timer.
Error logging capability:        (0x01) Error logging supported.
General Purpose Logging supported.
Short self-test routine
recommended polling time: (   2) minutes.
Extended self-test routine
recommended polling time: (  40) minutes.
SCT capabilities:        (0x003d) SCT Status supported.
SCT Error Recovery Control supported.
SCT Feature Control supported.
SCT Data Table supported.

SMART Attributes Data Structure revision number: 1
Vendor Specific SMART Attributes with Thresholds:
ID# ATTRIBUTE_NAME          FLAGS    VALUE WORST THRESH FAIL RAW_VALUE
  9 Power_On_Hours          -O--CK   095   095   000    -    21435
12 Power_Cycle_Count       -O--CK   092   092   000    -    7742
175 Program_Fail_Count_Chip -O--CK   100   100   010    -    0
176 Erase_Fail_Count_Chip   -O--CK   100   100   010    -    0
177 Wear_Leveling_Count     PO--C-   090   090   005    -    110
178 Used_Rsvd_Blk_Cnt_Chip  PO--C-   100   100   010    -    0
179 Used_Rsvd_Blk_Cnt_Tot   PO--C-   100   100   010    -    0
180 Unused_Rsvd_Blk_Cnt_Tot PO--C-   100   100   010    -    6240
181 Program_Fail_Cnt_Total  -O--CK   100   100   010    -    0
182 Erase_Fail_Count_Total  -O--CK   100   100   010    -    0
183 Runtime_Bad_Block       PO--C-   100   100   010    -    0
184 End-to-End_Error        PO--CK   100   100   097    -    0
187 Reported_Uncorrect      -O--CK   100   100   000    -    0
190 Airflow_Temperature_Cel -O--CK   069   046   000    -    31
195 Hardware_ECC_Recovered  -O-RC-   200   200   000    -    0
198 Offline_Uncorrectable   ----CK   100   100   000    -    0
199 UDMA_CRC_Error_Count    -OSRCK   253   253   000    -    0
233 Media_Wearout_Indicator -O-RCK   199   199   000    -    2462328
234 Unknown_Attribute       -O--C-   100   100   000    -    0
235 Unknown_Attribute       -O--C-   099   099   000    -    291
236 Unknown_Attribute       -O--C-   099   099   000    -    74
237 Unknown_Attribute       -O--C-   099   099   000    -    110
238 Unknown_Attribute       -O--C-   100   100   000    -    0
                            ||||||_ K auto-keep
                            |||||__ C event count
                            ||||___ R error rate
                            |||____ S speed/performance
                            ||_____ O updated online
                            |______ P prefailure warning

General Purpose Log Directory Version 1
SMART           Log Directory Version 1 [multi-sector log support]
Address    Access  R/W   Size  Description
0x00       GPL,SL  R/O      1  Log Directory
0x01       GPL,SL  R/O      1  Summary SMART error log
0x02       GPL,SL  R/O      1  Comprehensive SMART error log
0x03       GPL,SL  R/O      1  Ext. Comprehensive SMART error log
0x06       GPL,SL  R/O      1  SMART self-test log
0x07       GPL,SL  R/O      1  Extended self-test log
0x09       GPL,SL  R/W      1  Selective self-test log
0x10       GPL,SL  R/O      1  NCQ Command Error log
0x11       GPL,SL  R/O      1  SATA Phy Event Counters log
0x30       GPL,SL  R/O      1  IDENTIFY DEVICE data log
0x80-0x9f  GPL,SL  R/W     16  Host vendor specific log
0xa0       GPL,SL  VS      16  Device vendor specific log

SMART Extended Comprehensive Error Log Version: 1 (1 sectors)
No Errors Logged

SMART Extended Self-test Log Version: 1 (1 sectors)
Num  Test_Description    Status                  Remaining  LifeTime(hours)  LBA_of_first_error
# 1  Short offline       Completed without error       00%     21374         -
# 2  Short offline       Completed without error       00%      1408         -

SMART Selective self-test log data structure revision number 1
SPAN  MIN_LBA  MAX_LBA  CURRENT_TEST_STATUS
    1        0        0  Not_testing
    2        0        0  Not_testing
    3        0        0  Not_testing
    4        0        0  Not_testing
    5        0        0  Not_testing
  255        0    65535  Read_scanning was never started
Selective self-test flags (0x0):
  After scanning selected spans, do NOT read-scan remainder of disk.
If Selective self-test is pending on power-up, resume after 0 minute delay.

SCT Status Version:                  3
SCT Version (vendor specific):       256 (0x0100)
Device State:                        SCT command executing in background (5)
Current Temperature:                    31 Celsius
Power Cycle Min/Max Temperature:     29/40 Celsius
Lifetime    Min/Max Temperature:      0/70 Celsius
Under/Over Temperature Limit Count:   0/0

SCT Temperature History Version:     3 (Unknown, should be 2)
Temperature Sampling Period:         1 minute
Temperature Logging Interval:        1 minute
Min/Max recommended Temperature:      0/70 Celsius
Min/Max Temperature Limit:            0/70 Celsius
Temperature History Size (Index):    128 (22)

Index    Estimated Time   Temperature Celsius
  23    2021-06-22 06:36    32  *************
...    ..( 25 skipped).    ..  *************
  49    2021-06-22 07:02    32  *************
  50    2021-06-22 07:03    33  **************
...    ..( 21 skipped).    ..  **************
  72    2021-06-22 07:25    33  **************
  73    2021-06-22 07:26    32  *************
...    ..(  7 skipped).    ..  *************
  81    2021-06-22 07:34    32  *************
  82    2021-06-22 07:35    31  ************
  83    2021-06-22 07:36    32  *************
...    ..(  3 skipped).    ..  *************
  87    2021-06-22 07:40    32  *************
  88    2021-06-22 07:41    31  ************
...    ..( 14 skipped).    ..  ************
103    2021-06-22 07:56    31  ************
104    2021-06-22 07:57    30  ***********
105    2021-06-22 07:58    30  ***********
106    2021-06-22 07:59    31  ************
...    ..(  2 skipped).    ..  ************
109    2021-06-22 08:02    31  ************
110    2021-06-22 08:03    30  ***********
...    ..( 15 skipped).    ..  ***********
126    2021-06-22 08:19    30  ***********
127    2021-06-22 08:20    29  **********
...    ..(  4 skipped).    ..  **********
   4    2021-06-22 08:25    29  **********
   5    2021-06-22 08:26    30  ***********
...    ..( 10 skipped).    ..  ***********
  16    2021-06-22 08:37    30  ***********
  17    2021-06-22 08:38    31  ************
...    ..(  4 skipped).    ..  ************
  22    2021-06-22 08:43    31  ************

SCT Error Recovery Control:
           Read: Disabled
          Write: Disabled

Device Statistics (GP/SMART Log 0x04) not supported

Pending Defects log (GP Log 0x0c) not supported

SATA Phy Event Counters (GP Log 0x11)
ID      Size     Value  Description
0x0001  2            0  Command failed due to ICRC error
0x0002  2            0  R_ERR response for data FIS
0x0003  2            0  R_ERR response for device-to-host data FIS
0x0004  2            0  R_ERR response for host-to-device data FIS
0x0005  2            0  R_ERR response for non-data FIS
0x0006  2            0  R_ERR response for device-to-host non-data FIS
0x0007  2            0  R_ERR response for host-to-device non-data FIS
0x0008  2            0  Device-to-host non-data FIS retries
0x0009  2            3  Transition from drive PhyRdy to drive PhyNRdy
0x000a  2            2  Device-to-host register FISes sent due to a COMRESET
0x000b  2            0  CRC errors within host-to-device FIS
0x000d  2            0  Non-CRC errors within host-to-device FIS
0x000f  2            0  R_ERR response for host-to-device data FIS, CRC
0x0010  2            0  R_ERR response for host-to-device data FIS, non-CRC
0x0012  2            0  R_ERR response for host-to-device non-data FIS, CRC
0x0013  2            0  R_ERR response for host-to-device non-data FIS, non-CRC


I have a HP t620 plus that I've been using for years as a pfSense router. I wanted to switch to OPNsense so I can use ZeroTier.

When I use a USB Drive to install OPNsense everything works file until I install updates. Once it reboots after updating the system it can no longer find the boot drive.

I went though and installed it again with MBR selected this time and the same thing happens. The next thing I tried to do was install it again and just install the ZeroTier package without updating the system and it fails to find the boot drive again. If I install OPNsense and not install any packages or do any updates and do a reboot it comes right back up.

Next I installed the latest BIOS firmware to see if that would resolve the issue and the same problem keeps happening.

Is there anything else that I can do to get system to work after installing updates or packages?