Trying to upgrade from 25.7.4 to 25.7.5 but it Crashes and Reboots

[thadrumr]

I am trying to upgrade from 25.7.4 to 25.7.5 but I get the firewall crashes.  If I try and submit the firmware upgrade error I get the following error.
Fatal error: Uncaught Error: Call to undefined function curl_file_create() in /usr/local/www/crash_reporter.php:65 Stack trace: #0 /usr/local/www/crash_reporter.php(161): upload_crash_report(Array, 'OPNsense/25.7.4') #1 {main} thrown in /usr/local/www/crash_reporter.php on line 65

This is the error in the crash reporter.

[14-Oct-2025 17:03:59 America/New_York] PHP Fatal error:  Uncaught Error: Call to undefined function curl_file_create() in /usr/local/www/crash_reporter.php:65
Stack trace:
#0 /usr/local/www/crash_reporter.php(161): upload_crash_report(Array, 'OPNsense/25.7.4')
#1 {main}
  thrown in /usr/local/www/crash_reporter.php on line 65
[14-Oct-2025 21:04:20 UTC] PHP Warning:  PHP Startup: Unable to load dynamic library 'curl.so' (tried: /usr/local/lib/php/20230831/curl.so (Shared object "libcurl.so.4" not found, required by "curl.so"), /usr/local/lib/php/20230831/curl.so.so (Cannot open "/usr/local/lib/php/20230831/curl.so.so")) in Unknown on line 0
[14-Oct-2025 21:04:56 UTC] PHP Warning:  PHP Startup: Unable to load dynamic library 'curl.so' (tried: /usr/local/lib/php/20230831/curl.so (Shared object "libcurl.so.4" not found, required by "curl.so"), /usr/local/lib/php/20230831/curl.so.so (Cannot open "/usr/local/lib/php/20230831/curl.so.so")) in Unknown on line 0


It seems to error out when trying to upgrade these two packages.

opnsense: 25.7.4 -> 25.7.5

php83-phpseclib: 3.0.46 -> 3.0.47

[cookiemonster]

I suspect the filesystem is in a bad state. I'd urgently save your config as you might need to re-install.
How it got there? Perhaps a faulty storage.

[thadrumr]

I suspect the filesystem is in a bad state. I'd urgently save your config as you might need to re-install.
How it got there? Perhaps a faulty storage.

Man you were spot on!!!!! I luckily downloaded a backup of the config yesterday evening.  I went to my parents house today to do a file system check but the hard drive completely died once I did a reboot.  The downside is the only spare hard drive I had laying around was an old 500GB Apple Sata 2.5" hard drive from a Macbook pro.  This is of course WAY overkill for a firewall but it works and it's 5400rpm so should keep heat down in the small enclosure.  It worked fine though once I re-installed it and imported my backup config.  Moral of the story always have a backup!!!.

[cookiemonster]

phew, just in time hey! There are plugins available to save configs regularly like sftp and to nextcloud.