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I've seen the reports of eMMC issues- that was the first thing I expected to be the problem. Thank you for the suggestion- I might try working this out with bare FreeBSD once I get a replacement device. At this point I'm going to just start looking for some new hardware- it's time!

In the meantime, I was able to successfully reinstall 24.7, upgrade to 24.7.12, and restore an old backup so things are at least running again. Did tempt fate by trying to use the webgui to upgrade to 25.1 again, and it failed again, so it looks like sticking with 24.7.12 for the time being is my only option with this device.

Looking for any advice or suggestions folks may have. I pulled the trigger on upgrading my device to 25.1 from the 24.7 series, and it failed spectacularly. I'm using a Netgate SG-2440 and I'm currently unable to even boot into recovery media (imaged from the 25.1 Nano media). The boot process hangs right after identifying the built-in eMMC module (log posted below, this is the output using the console port). The eMMC media is identified as Generic Ultra HS-COMBO 1.98.

This below log is from booting off a 25.1 USB drive flashed with the OPNSense Nano image (same result using the serial image).

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...
usb_msc_auto_quirk: UQ_MSC_NO_SYNC_CACHE set for USB mass storage device Generic Ultra Fast Media (0x0424:0x2240)
usb_msc_auto_quirk: UQ_MSC_NO_START_STOP set for USB mass storage device Generic Ultra Fast Media (0x0424:0x2240)
ugen0.4: <Generic Ultra Fast Media> at usbus0
umass1 on uhub1
umass1: <Generic Ultra Fast Media, class 0/0, rev 2.00/1.98, addr 4> on usbus0
umass1:  SCSI over Bulk-Only; quirks = 0xc105
umass1:5:1: Attached to scbus5
Root mount waiting for: CAM
da0 at umass-sim0 bus 0 scbus4 target 0 lun 0
da0: <SanDisk Ultra Fit 1.00> Removable Direct Access SPC-4 SCSI device
da0: Serial Number 01018e29fa8d7c026648c44afd9d70ae82c9ac319038584f36cc5c42e296
da0: 40.000MB/s transfers
da0: 117360MB (240353280 512 byte sectors)
da0: quirks=0x2<NO_6_BYTE>\
da1 at umass-sim1 bus 1 scbus5 target 0 lun 0
da1: <Generic Ultra HS-COMBO 1.98> Removable Direct Access SCSI device
da1: Serial Number 000000225001
da1: 40.000MB/s transfers
da1: 7456MB (15269888 512 byte sectors)
da1: quirks=0x2<NO_6_BYTE>
Dual Console: Serial Primary, Video Secondary
ZFS filesystem version: 5
ZFS storage pool version: features support (5000)
igb0: link state changed to UP
igb1: link state changed to UP
ichsmb0: <Intel Avoton SMBus controller> port 0xefa0-0xefbf mem 0xdfff5800-0xdfff581f irq 22 at device 31.3 on pci0
smbus0: <System Management Bus> on ichsmb0
lo0: link state changed to UP
igb0: link state changed to UP
igb1: link state changed to UP
After the boot process hits the point where the ichsmb0, smbus0, etc. lines are, the process just hangs. No further progress is made, and I've left it for hours. I was able to get into an ancient version of PFsense (2.7.3) using an old drive hooked up to the SG2440's internal SATA port, and was able to successfully mount the storage, recover my configuration backups, and zero out the eMMC, so as far as I can tell, the eMMC is still viable.

The only modifications I made to the imaged boot media was to add a /boot/loader.conf.local with the below contents to enable the console.

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hint.uart.0.flags="0x0"
hint.uart.1.flags="0x10"
comconsole_speed="115200"
comconsole_port="0x2F8"
console="comconsole"
Just hoping to at least get something up so I can limp along until I can get some new hardware.

I have been able to successfully boot off 24.7 media, and I'm in the process of reinstalling.