pfSense

Some installations as recent as Plus 22.01 / CE 2.6.0 have EFI partitions that were created and/or populated by the old EFIFAT image method. This means that while the EFI partition is 200M, the EFI filesystem is only around 700KB. As a result, these installations are unable to upgrade to recent versions successfully as the loader cannot be updated.

This can be worked around by reformatting the EFI partition directly and copying the appropriate files back into place, as described in this forum post: https://forum.netgate.com/post/1140955

# mkdir -p /boot/efi
# mount_msdosfs /dev/msdosfs/EFISYS /boot/efi
# mkdir -p /tmp/efitmp
# cp -Rp /boot/efi/* /tmp/efitmp
# umount /boot/efi
# newfs_msdos -F 32 -c 1 -L EFISYS /dev/msdosfs/EFISYS
# mount_msdosfs /dev/msdosfs/EFISYS /boot/efi
# cp -Rp /tmp/efitmp/* /boot/efi/

There are some potential complications there. For example, the EFI filesystem may not be labeled that way, it could be /dev/gpt/EFISYS or it may have no label at all.

Marked as Plus 24.03/CE 2.8.0 but if it can be fixed in the pfSense-boot package the fix could be picked back to 23.09.1/2.7.2.