vSAN hosts get PSOD while exiting maintenance mode after upgrading ESXi and hardware profile

Products

• VMware vSAN

Issue/Introduction

1. New patch is installed on all hosts at the same time under normal status.
2. Hardware profile is changed/upgraded then
3. The host can boot up into maintenance mode but get PSOD with vSAN  after exiting maintenance mode
4. Panic Message: @BlueScreen: Failed at bora/modules/vmkernel/lsom/lsom_commit_flusher.c:2575 -- VMK_ASSERT(cfDisableAssert || LSNEntryLessThan(entry, cfParams->gcpEntry)) 
5. The host will never boot up normally but can boot up without vSAN module 
6. If no hardware profile change, the host can boot up and exit maintenance mode successfully.

Cause

Hardware profile change caused vSAN module boot up issue.

Resolution

Following VMware vSAN upgrade best practices to upgrade the vSAN cluster without any HW change.
Any hardware change should be verified by hardware vendor and applied on a healthy vSAN cluster.

If you recently swapped out a physical drive from this host without first properly removing it logically from vSAN disk group, this KB will help you resolve the PSOD issue.