“Cannot execute upgrade script on host” During upgrade from ESXi 6.0 u3 to 6.5

After upgrading vCenter from 6.0 to 6.5 i created an VUM upgrade baseline for the hosts with Dell image (VMware-VMvisor-Installer-6.5.0-4564106.x86_64-Dell_Customized-A00.iso).   During remediation i received the event “Cannot execute upgrade script on host”.

 

2017-03-13 22_00_39-vSphere Web Client

After trying the steps in KB 2007163 https://kb.vmware.com/selfservice/microsites/search.do?language=en_US&cmd=displayKC&externalId=2007163 I did not see the events the described in the vua.log

I did see one more event on the host just before the remediation failed about vfat being full so I checked storage on the host.
[root@esx01:/tmp] df -h
Filesystem   Size   Used Available Use% Mounted on
VMFS-5     136.0G  41.6G     94.4G  31% /vmfs/volumes/LocalESXi1_15K
vfat       249.7M 168.9M     80.9M  68% /vmfs/volumes/c21f0def-ab368d35-c3e1-0a143e19c920
vfat       249.7M 144.2M    105.6M  58% /vmfs/volumes/08bb34e6-ff79c24e-6fc8-a6154e41cb2e
vfat       285.8M 285.4M    424.0K 100% /vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994
vsan         1.1T 827.9G    250.2G  77% /vmfs/volumes/vsanDatastore

 

One of them showed 100% full and looking at the contents of that volume i found the update package for 6.5.0 and some logs from when I ran VSAN observer last year.

[root@esx01:/vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994] cd packages
[root@esx01:/vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994/packages] ls
6.5.0

I deleted the 6.5.0 folder because it will re stage again during remediation.
[root@esx01:/vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994/packages] rm -r 6.5.0

And I cleared out the “vsatraces” directory
[root@esx01:/vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994] cd vsantraces
[root@esx01:/vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994/vsantraces] ls -l
total 85064
-rwx——    1 root     root        241287 Mar 23  2016 vsanObserver–2016-03-22T23h46m01s.gz
-rwx——    1 root     root        238734 Mar 23  2016 vsanObserver–2016-03-23T00h08m01s.gz
-rwx——    1 root     root        238653 Mar 23  2016 vsanObserver–2016-03-23T00h30m02s.gz
-rwx——    1 root     root        108499 Mar 23  2016 vsanObserver–2016-03-23T00h52m01s.gz
-rwx——    1 root     root         27630 Mar 23  2016 vsanObserver–2016-03-23T01h04m01s.gz
-rwx——    1 root     root      17825792 Mar 22  2016 vsantraces–2016-03-22T23h55m21s048.gz
-rwx——    1 root     root      19468628 Mar 22  2016 vsantraces–2016-03-22T23h55m38s332.gz
-rwx——    1 root     root      20114458 Mar 22  2016 vsantraces–2016-03-22T23h55m54s655.gz
-rwx——    1 root     root      20300352 Mar 22  2016 vsantraces–2016-03-22T23h56m11s397.gz
-rwx——    1 root     root       5566550 Mar 23  2016 vsantraces–2016-03-22T23h56m32s364.gz
-rwx——    1 root     root        257228 Mar 23  2016 vsantraces–2016-03-23T01h03m45s026.gz
-rwx——    1 root     root           192 Mar 23  2016 vsantraces.index
-rwx——    1 root     root       2702730 Mar 23  2016 vsantracesUrgent–2016-03-22T06h09m58s710.gz
-rwx——    1 root     root         10423 Mar 23  2016 vsantracesUrgent–2016-03-23T01h03m45s139.gz
-rwx——    1 root     root            96 Mar 23  2016 vsantracesUrgent.index

[root@esx01:~] cd /vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994
[root@esx01:/vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994] rm -r vsantraces
[root@esx01:/vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994/packages] df -h
Filesystem   Size   Used Available Use% Mounted on
VMFS-5     136.0G  41.6G     94.4G  31% /vmfs/volumes/LocalESXi1_15K
vfat       249.7M 168.9M     80.9M  68% /vmfs/volumes/c21f0def-ab368d35-c3e1-0a143e19c920
vfat       249.7M 144.2M    105.6M  58% /vmfs/volumes/08bb34e6-ff79c24e-6fc8-a6154e41cb2e
vfat       285.8M 120.0K    285.7M   0% /vmfs/volumes/54dffa2c-42ac85b2-abe0-002219687994
vsan         1.1T 828.1G    249.9G  77% /vmfs/volumes/vsanDatastore

Once space was freed up I was able to use VUM to do the upgrade to ESXi 6.5.

 

2017-03-13 23_00_47-esx01.mira.lan - VMware ESXi

 

 

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