Quick update:
I tested the hard drive in Bios and seemed working. I reinstalled OPNsense on UFS file system. The disk space problem is gone. I updated then restored my backup. Well, I had my VLANs mixed up. Somehow, the firewall rules and DHCP reservations for VLAN X would show up under VLAN Y. The interface assignment have not changed. I have to re-do it all manually. I am not sure there is a better way to do it but this is my primary home firewall/router. Terrible experience!!
I tested the hard drive in Bios and seemed working. I reinstalled OPNsense on UFS file system. The disk space problem is gone. I updated then restored my backup. Well, I had my VLANs mixed up. Somehow, the firewall rules and DHCP reservations for VLAN X would show up under VLAN Y. The interface assignment have not changed. I have to re-do it all manually. I am not sure there is a better way to do it but this is my primary home firewall/router. Terrible experience!!