vCenter patch fails at 0% with [Errno 2] No such file or directory: patching_backup_config.json

Products

• VMware vCenter Server

Issue/Introduction

• The issue occurs while patching the VMware vCenter Server Appliance (VCSA) using a manually mounted ISO. The patching process fails immediately at 0% progress and displays the following error:

[Errno 2] No such file or directory: '/storage/seat/software-update*/stage/update/patching_backup_config.json'

Environment

VMware vCenter Server 8.x

Cause

This issue occurs when a full vCenter Server installation or upgrade ISO (e.g., VMware-VCSA-all-*.iso) is mounted to the appliance instead of the required Full Patch (FP) ISO image (e.g., VMware-vCenter-Server-Appliance-*-patch-FP.iso). The standard installer ISO lacks the necessary metadata and directory structures required for the patching workflow.

Resolution

Note: Verify that a working backup exists before you proceed. Follow the Snapshot Best practices for vCenter Server Virtual Machines for guidance.

1.  Log in to the vCenter Server Appliance as the root user using an SSH client.
2. To unstage the staged patches, run the following command
     /bin/appliancesh/software-packages unstage
3. Stop the Appliance Management service: 
     service-control --stop applmgmt
4. Remove existing update and staging files:
   Note: These commands permanently delete downloaded or partially staged patch files. This is destructive and requires a complete re-download or re-mount of the correct ISO.
     rm -rf /storage/core/software-update/updates/*
  rm -rf /storage/core/software-update/stage/*
  rm -rf /storage/db/patching.db
  mv /storage/core/software-packages/staged-configuration.json /storage/core
  mv /etc/applmgmt/appliance/software_update_state.conf /storage/core
5. Start the Appliance Management service:
     service-control --start applmgmt
6. Download the vCenter Full Patch (FP) ISO. Follow Download vCenter Server patches and ISOs for latest releases for guidance.
7. Mount ISO:
   1. Right-click the VCSA VM in the vSphere Client > Edit Settings.
   2. Under CD/DVD Drive, select Datastore ISO File, browse to the FP ISO, and select Connected.
8. Log in to the VAMI (https://<vcenter-ip/FQDN>:5480) and initiate the update.