ESXi host patch failed with "VFAT_CORRUPTION ERROR: Failed to run dosfsck check on vFAT bootbank partitions: Not found"

Products

• VMware vSphere ESXi 8.0
• VMware vSphere ESXi 7.0

Issue/Introduction

• ESXi host patch fails with below error in esxupdate.log when patching with "esxcli software profile update" command:
  
  esxupdate[2119922]: esximage.Errors.HardwareError: Hardware precheck of profile ESXi-8.0U3d-24585383-standard failed with errors: <VFAT_CORRUPTION ERROR: Failed to run dosfsck check on vFAT bootbank partitions: Not found>
  
  
• When patching with vCenter Lifecycle Manager, the reported error could be "/usr/sbin/esxupdate returned with exit status: 30."
• "df -h" command shows there's only BOOTBANK2 partition but no BOOTBANK1

Environment

VMware vSphere ESXi 8.0
VMware vSphere ESXi 7.0 

Cause

ESXi host is missing one bootbank partition.

Resolution

Reinstall ESXi host and can directly reinstall with target version.

Additional Information

For detailed steps to reinstall ESXi host, please refer to: Installing ESXi.