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Customer planned to upgrade the FTD (Cisco Firepower 1140 Threat Defense) in HA from 7.4.2 to 7.6.2 - Secondary FTD got upgraded successfully to 7.6.2. - Primary FTD upgrade failed. - The Primary FTD upgrade failed with the following error log message: ui: Upgrade in progress: (14% done.24 mins to reboot). Preparing to upgrade... (200_pre/200_enable_maintenance_mode.pl) ui:__[] Fatal error: Upgrade Failed (Device not operational): Error running script 200_pre/200_enable_maintenance_mode.pl. 250828 01:29:21:170] Current backup-config.cfg size: 14945 , remaining size: 2041 [250828 01:29:23:178] Current backup-config.cfg size: 14945 , remaining size: 2041 [250828 01:29:23:186] It seems startup-config file copy hung or non-progressing, need to come out [250828 01:29:23:193] Retaining /mnt/disk0/backup-config.cfg file as /mnt/disk0/backup-config.cfg_2025-08-28-01-29-23 in case of invalid checksum or partial copy [250828 01:29:23:503] : END - Entering Maintenance mode return code rc= 2 rc was 2, Exiting ... Backed up file /ngfw/var/sf/upgrades_backup/ThreatUpgrade.pm_7.4.2 doesn't exist. Removing the directory /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade/ unlink /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade/ThreatUpgrade.pm rmdir /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade Entering maintenance mode failed. rc=2 Startup-config backup operation failed, current backup-config.cfg size: 14945 , startup-config size: 16986 remaining size: 2041 Aborting upgrade Error entering Maintenance Mode: Startup-config backup operation failed, current backup-config.cfg size: 14945 , startup-config size: 16986 remaining size: 2041 Aborting upgrade cannot unlink file for /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade/ThreatUpgrade.pm: Read-only file system at 200_pre/200_enable_maintenance_mode.pl line 135. cannot restore permissions to 0100444 for /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade/ThreatUpgrade.pm: Read-only file system at 200_pre/200_enable_maintenance_mode.pl line 135. cannot remove directory for /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade: Read-only file system at 200_pre/200_enable_maintenance_mode.pl line 135. Removed maintenance-state file (/ngfw/var/log/sf/Cisco_FTD_SSP_FP1K_Upgrade-7.6.2/maint_state) Fatal error: Failure to enter maintenance mode: rc=2, error=:Startup-config backup operation failed, current backup-config.cfg size: 14945 , startup-config size: 16986 remaining size: 2041 Aborting upgrade Aug 28, 2025, 8:10 AM Other
FTD (managed by FMC) upgrade from 7.4.2 to 7.6.2
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- Checked the disk space on the Primary FTD, and it appears to be normal. root@Ese-wifi-ftd-1:/mnt/disk0# df -Th Filesystem Type Size Used Avail Use% Mounted on rootfs rootfs 7.3G 7.5M 7.3G 1% / devtmpfs devtmpfs 7.3G 80M 7.2G 2% /dev tmpfs tmpfs 7.8G 508K 7.8G 1% /run /dev/sda1 ext3 7.3G 1.1G 5.9G 16% /mnt/boot /dev/sda2 ext3 922M 34M 841M 4% /opt/cisco/config /dev/sda3 ext3 922M 21M 854M 3% /opt/cisco/platform/logs /dev/sda5 xfs 149G 25G 125G 17% /opt/cisco/csp /dev/sda4 ext3 28G 148K 26G 1% /var/data/cores cgroup_root tmpfs 7.8G 0 7.8G 0% /dev/cgroups none tmpfs 371M 0 371M 0% /dev/shm/snort tmpfs tmpfs 1.0M 0 1.0M 0% /var/data/cores/sysdebug/tftpd_logs root@Ese-wifi-ftd-1:/mnt/disk0# du -shx * 4.0K asa-cmd-server.log 16K backup-config.cfg_2025-08-29-00-24-03 16K backup-config.cfg_2025-08-29-00-57-46 4.0K boot 0 coredumpfsys 0 coredumpfsysimage.bin 4.0K coredumpinfo 192K csco_config 0 cspCfg.xml 4.0K hitcnt_del_ruleid_list 184M log 8.0K modified-config.cfg 0 packet-tracer 4.0K snortpacketinfo.conf 16K string 4.0K troubleshoot_file root@Ese-wifi-ftd-1:/mnt/disk0# - Based on the error, there seems to have been an issue while copying the startup-config file contents into backup-config.cfg under /mnt/disk0. - Deleted all the previous backup-config.cfg file under /mnt/disk0 - Manually copied the contents of startup-config to backup-config.cfg using the command below: cp .private/startup-config backup-config.cfg - Checked the hash values of both files; they were same: root@Ese-wifi-ftd-1:/mnt/disk0# md5sum backup-config.cfg d26d1e79a14fa01547446ed1bb78844f backup-config.cfg root@Ese-wifi-ftd-1:/mnt/disk0/.private# md5sum startup-config d26d1e79a14fa01547446ed1bb78844f startup-config - Initiated the upgrade again through FTD but it failed with the same error message. ui: Upgrade in progress: (11% done.25 mins to reboot). Preparing to upgrade... (200_pre/006_check_snort.sh) ui: Upgrade in progress: (14% done.24 mins to reboot). Preparing to upgrade... (200_pre/200_enable_maintenance_mode.pl) ui:__[] Fatal error: Upgrade Failed (Device not operational): Error running script 200_pre/200_enable_maintenance_mode.pl. 50829 01:28:59:579] Current backup-config.cfg size: 15025 , remaining size: 1961 [250829 01:28:59:591] It seems startup-config file copy hung or non-progressing, need to come out [250829 01:28:59:602] Retaining /mnt/disk0/backup-config.cfg file as /mnt/disk0/backup-config.cfg_2025-08-29-01-28-59 in case of invalid checksum or partial copy [250829 01:28:59:637] : END - Entering Maintenance mode return code rc= 2 rc was 2, Exiting ... Backed up file /ngfw/var/sf/upgrades_backup/ThreatUpgrade.pm_7.4.2 doesn't exist. Removing the directory /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade/ unlink /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade/ThreatUpgrade.pm rmdir /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade Entering maintenance mode failed. rc=2 Startup-config backup operation failed, current backup-config.cfg size: 15025 , startup-config size: 16986 remaining size: 1961 Aborting upgrade Error entering Maintenance Mode: Startup-config backup operation failed, current backup-config.cfg size: 15025 , startup-config size: 16986 remaining size: 1961 Aborting upgrade cannot unlink file for /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade/ThreatUpgrade.pm: Read-only file system at 200_pre/200_enable_maintenance_mode.pl line 135. cannot restore permissions to 0100444 for /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade/ThreatUpgrade.pm: Read-only file system at 200_pre/200_enable_maintenance_mode.pl line 135. cannot remove directory for /ngfw/var/sf/lib/perl/5.32.1/SF/Upgrade: Read-only file system at 200_pre/200_enable_maintenance_mode.pl line 135. Removed maintenance-state file (/ngfw/var/log/sf/Cisco_FTD_SSP_FP1K_Upgrade-7.6.2/maint_state) Fatal error: Failure to enter maintenance mode: rc=2, error=:Startup-config backup operation failed, current backup-config.cfg size: 15025 , startup-config size: 16986 remaining size: 1961 Aborting upgrade
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