[j-nsp] problems with compact-flash

[Kurt Bauer]

Hi list,

I have the following, rather serious, problem with a M5:

After a power-loss it is no longer possible to boot from compact flash,
the router hangs in the middle of the boot process, right after the tw
lines, which say:
fxp0: .....
fxp1: .....

When I boot from Harddisk it works fine, but I cannot see the
compact-flash when I make 'show system storage':

Filesystem  1K-blocks     Used    Avail Capacity  Mounted on
/dev/ad1s1a     73255    25162    42233    37%    /
devfs              16       16        0   100%    /dev/
/dev/vn0         9828     9828        0   100%    /packages/mnt/jbase
devfs              16       16        0   100%    /dev/
/dev/vn1        16006    16006        0   100%   
/packages/mnt/jkernel-5.4R2.4
/dev/vn2        20224    20224        0   100%   
/packages/mnt/jpfe-5.4R2.4
/dev/vn3         1370     1370        0   100%   
/packages/mnt/jdocs-5.4R2.4
/dev/vn4         7794     7794        0   100%   
/packages/mnt/jroute-5.4R2.4
mfs:122        762223        3   701243     0%    /tmp
/dev/ad1s1e     17703        6    16281     0%    /config
procfs              4        4        0   100%    /proc
/dev/ad1s1f   7156052    99045  6484523     2%    /var


I tried a few things in the shell, with the following results:

-) It's not possible to mount the flash:
   mount: /dev/ad0: Operation not permitted

-) 'fdisk /dev/ad0' gives the following:
******* Working on device /dev/ad0 *******
parameters extracted from in-core disklabel are:
cylinders=734 heads=8 sectors/track=32 (256 blks/cyl)

parameters to be used for BIOS calculations are:
cylinders=734 heads=8 sectors/track=32 (256 blks/cyl)

Media sector size is 512
Warning: BIOS sector numbering starts with sector 1
Information from DOS bootblock is:
The data for partition 1 is:
sysid 165,(FreeBSD/NetBSD/386BSD)
    start 0, size 187904 (91 Meg), flag 80 (active)
	beg: cyl 0/ sector 1/ head 0;
	end: cyl 733/ sector 32/ head 7
The data for partition 2 is:
<UNUSED>
The data for partition 3 is:
<UNUSED>
The data for partition 4 is:
<UNUSED>

-) and finally, 'fsck /dev/ad0' gives the following:
** /dev/ad0
** Last Mounted on /mnt
** Phase 1 - Check Blocks and Sizes

CANNOT READ: BLK 65600
CONTINUE? [yn] y

THE FOLLOWING DISK SECTORS COULD NOT BE READ: 65600, 65601, 65602,
65610, 65611,
** Phase 2 - Check Pathnames
** Phase 3 - Check Connectivity
** Phase 4 - Check Reference Counts
** Phase 5 - Check Cyl groups
1822 files, 43045 used, 29658 free (42 frags, 3702 blocks, 0.1%
fragmentation)

***** FILE SYSTEM STILL DIRTY *****

***** PLEASE RERUN FSCK *****


As it seems, there are some none repairable sectors, is it somehow
possible to bypass them, e.g. reformat the flash, making a new
filesystem or something like this ??


And if yes, which is the best way to get the software back from the
harddisk to the flash ??


Or if nothing helps, which hardware part do I have to replace, hopefully
not the entire routing engine or the FEB.


TIA for your help,

best regards,

Kurt