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Cisco ASA 5505 dumped config,software, and license upon upgrade to 8.0.4 OS

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Last Modified: 2012-06-21
We have 5 of our ASA 5505 security devices that have erased all of their configuration, and software images upon attempting to upgrade to ASA804-k8.  When the systems boot we get to "Launching BootLoader..." and the systems hang.  I can break into rommon and boot from a tftp image, from there I can load a config, save it to startup-config, and copy the image down from tftp, however the systems are still hanging on the bootloader after reboot.  Also they showing the license key as invalid when booting from tftp.

The upgrade was run in two phases, the software images were pushed to the devices and ensured that they copied fine.  secondly a job was run using kiwi cat tools to run the following commands on the  the devices:

conf t
no boot system disk0:/asa802-k8.bin
boot system disk0:/asa804-k8.bin
boot system disk0:/asa802-k8.bin
asdm image disk0:/asdm-615.bin
write mem
reload noconfirm

80+ worked fine using this technique.  5 blew up and have not worked since.  Does anyone have any experience with these devices hanging on bootloader....
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