Failed at bora/modules/vmkernel/virsto/io_flow/flusher.c:299 PSOD on vSAN host

Products

• VMware vSAN

Issue/Introduction

Symptoms:

         

• Affected vSAN host was running on 7.0 u3.
• After the reboot, the host gets stuck at the vSAN recovery module and subsequently enters a panic state. This behavior goes in a loop.
  
• Disable vSAN at host boot and able to load the Esxi successfully.
  
  

Environment

VMware vSphere 7.x

Cause

The issue is due to one of the underlying disk reporting i/o error when vSAN recovery module attempts to verify and resync the metadata.

In /var/run/log/vmkernel.log, you will see the below events

2025-05-27T04:01:22.405Z cpu47:2098269)Vol3: 2128: Couldn't read volume header from naa.51402ec014de04c7:1: I/O error
2025-05-27T04:01:22.406Z cpu26:2098281)Vol3: 2128: Couldn't read volume header from naa.51402ec014de04c8:1: I/O error
2025-05-27T04:01:22.406Z cpu26:2098274)Vol3: 2128: Couldn't read volume header from naa.51402ec014de04c5:1: I/O error

Resolution

• Detach the problematic drive and reboot the host, vSAN recovery should successfully and the host should come back online.
• Contact the hardware vendor and replace the drive.