Unable to Upgrade to 25.7.1

[scr3wballl]

I ran into the same problem. I did a config backup, then fresh clean OS install, and import config, all is well, updated to latest version. Downtime less than 30 minutes.

[utkonos]

The eventual and successful fix was to do a config backup, fresh install (with ZFS this time), and config import. Clean and fast. A bit longer than 30 minutes but that's because I stopped to eat lunch while OPNsense copied itself to the drive.

Here are a few notes.

I was not able to get the config to read during the import config step during console boot from the USB installer (vga type). I had formatted the USB FAT32 and copied the config downloaded from the GUI to the USB. The installer recognized the da1 USB stick but was not able to find the config.xml.

The installer had difficulty with installing to the disk that still had the old OPNsense UFS partition. I tried a partial dd from /dev/zero, but there is still a secondary GPT table at the end of the disk that you should overwrite with zeros as well. Once all that is gone, the installer works just fine.

Since I could not get the config imported from a USB, I opted to configure just the WAN and LAN interfaces and nothing else. Once the install finished, I was able to connect a laptop to the LAN port and get to the default DHCP network and GUI. From there, importing the config via GUI worked flawlessly. After import and reboot, everything was back to normal and I was then able to perform the update that wasn't working in the first place.