Sysupgrade failed silently from 24.10.4 to 25.15.5 on TL-XDR6086

I recently downloaded a customized image from firmware selector for my TL-XDR6086 router. I use luci-app-sysupgrade to fresh the firmware, after reboot, it is still in old 24.10 version. I used the same process to upgrade from 23.05 to 24.10 succesfully. I am not sure where I should check in next step to solve the problem.

Your help is very much appreciated.

Here is the firmware selector log for my image.

STDERR
/builder/build_dir/target-aarch64_cortex-a53_musl/root-mediatek/etc/init.d/usteer: line 10: /lib/functions/network.sh: No such file or directory
/builder/build_dir/target-aarch64_cortex-a53_musl/root-mediatek/etc/init.d/usteer: line 11: /usr/share/libubox/jshn.sh: No such file or directory
/builder/build_dir/target-aarch64_cortex-a53_musl/root-mediatek/etc/init.d/usteer: line 12: /lib/functions.sh: No such file or directory
./etc/init.d/usteer: line 10: /lib/functions/network.sh: No such file or directory
./etc/init.d/usteer: line 11: /usr/share/libubox/jshn.sh: No such file or directory
./etc/init.d/usteer: line 12: /lib/functions.sh: No such file or directory
Pseudo file "dev" exists in source filesystem "/builder/build_dir/target-aarch64_cortex-a53_musl/root-mediatek/dev".
Ignoring, exclude it (-e/-ef) to override.
11489+1 records in
11489+1 records out
5882549 bytes (5.9 MB, 5.6 MiB) copied, 0.0174237 s, 338 MB/s
3620+1 records in
3621+0 records out
14831616 bytes (15 MB, 14 MiB) copied, 0.0163961 s, 905 MB/s
STDOUT
Checking 'true'... ok.
Checking 'false'... ok.
Checking 'working-make'... ok.
Checking 'case-sensitive-fs'... ok.
Checking 'proper-umask'... ok.
Checking 'perl-data-dumper'... ok.
Checking 'perl-findbin'... ok.
Checking 'perl-file-copy'... ok.
Checking 'perl-file-compare'... ok.
Checking 'perl-thread-queue'... ok.
Checking 'perl-ipc-cmd'... ok.
Checking 'tar'... ok.
Checking 'find'... ok.
Checking 'bash'... ok.
Checking 'xargs'... ok.
Checking 'patch'... ok.
Checking 'diff'... ok.
Checking 'cp'... ok.
Checking 'seq'... ok.
Checking 'awk'... ok.
Checking 'grep'... ok.
Checking 'egrep'... ok.
Checking 'getopt'... ok.
Checking 'realpath'... ok.
Checking 'stat'... ok.
Checking 'gzip'... ok.
Checking 'unzip'... ok.
Checking 'bzip2'... ok.
Checking 'wget'... ok.
Checking 'install'... ok.
Checking 'perl'... ok.
Checking 'python'... ok.
Checking 'python3'... ok.
Checking 'python3-distutils'... ok.
Checking 'python3-stdlib'... ok.
Checking 'file'... ok.
Checking 'which'... ok.
Checking 'ldconfig-stub'... ok.
Building images for mediatek - TP-Link TL-XDR6086
Packages: apk-mbedtls base-files ca-bundle dnsmasq dropbear firewall4 fitblk fstools kmod-crypto-hw-safexcel kmod-gpio-button-hotplug kmod-leds-gpio kmod-nft-offload libc libgcc libustream-mbedtls logd mtd netifd nftables odhcp6c odhcpd-ipv6only ppp ppp-mod-pppoe procd-ujail uboot-envtools uci uclient-fetch urandom-seed urngd wpad-mbedtls fitblk kmod-usb3 kmod-mt7915e kmod-mt7986-firmware mt7986-wo-firmware luci luci-app-attendedsysupgrade busybox luci-proto-ipv6 luci-proto-ppp luci-ssl luci-theme-bootstrap luci-app-usteer luci-app-tinyproxy luci-app-statistics collectd-mod-sensors adguardhome apk-mbedtls base-files ca-bundle dnsmasq dropbear firewall4 fitblk fstools kernel kmod-crypto-hw-safexcel kmod-gpio-button-hotplug kmod-leds-gpio kmod-mt7915e kmod-mt7986-firmware kmod-nft-offload kmod-usb3 libc libgcc libustream-mbedtls logd mt7986-wo-firmware mtd netifd nftables odhcp6c odhcpd-ipv6only ppp ppp-mod-pppoe procd-ujail uboot-envtools uci uclient-fetch urandom-seed urngd "base-files=1711~f5dae5ece4" "libc=1.2.5-r5" "kernel=6.12.94~5a6c1f71be683ae9980b15d3ce73e24d-r1"

OK: 0 B in 0 packages

Installing packages...
(  1/186) Installing libgcc1 (14.3.0-r5)
(  2/186) Installing libc (1.2.5-r5)
(  3/186) Installing ca-bundle (20260601-r1)
(  4/186) Installing adguardhome (0.107.76-r1)
(  5/186) Installing libmbedtls21 (3.6.6-r2)
(  6/186) Installing libubox20260213 (2026.06.19~7dd12784-r1)
(  7/186) Installing libuclient20201210 (2026.06.07~daad21fa-r1)
(  8/186) Installing uclient-fetch (2026.06.07~daad21fa-r1)
(  9/186) Installing zlib (1.3.1-r1)
( 10/186) Installing apk-mbedtls (3.0.5-r3)
( 11/186) Installing busybox (1.37.0-r6)
( 12/186) Installing ubi-utils (2.3.0-r1)
( 13/186) Installing libubus20251202 (2026.06.28~24864e78-r2)
( 14/186) Installing libuci20250120 (2025.12.02~66127cd7-r1)
( 15/186) Installing libjson-c5 (0.18-r1)
( 16/186) Installing libblobmsg-json20260213 (2026.06.19~7dd12784-r1)
( 17/186) Installing ubusd (2026.06.28~24864e78-r2)
( 18/186) Installing ubus (2026.06.28~24864e78-r2)
( 19/186) Installing ubox (2025.10.30~6f78fa49-r1)
( 20/186) Installing fstools (2026.05.23~16718b6e-r1)
( 21/186) Installing fwtool (2025.10.03~04cd252e-r1)
( 22/186) Installing jsonfilter (2026.03.16~b9034210-r1)
( 23/186) Installing jshn (2026.06.19~7dd12784-r1)
( 24/186) Installing libnl-tiny1 (2025.12.02~40493a65-r1)
( 25/186) Installing libudebug (2026.01.16~875e1a7a)
( 26/186) Installing libucode20230711 (2026.01.16~85922056-r1)
( 27/186) Installing ucode (2026.01.16~85922056-r1)
( 28/186) Installing ucode-mod-fs (2026.01.16~85922056-r1)
( 29/186) Installing ucode-mod-ubus (2026.01.16~85922056-r1)
( 30/186) Installing ucode-mod-uci (2026.01.16~85922056-r1)
( 31/186) Installing ucode-mod-uloop (2026.01.16~85922056-r1)
( 32/186) Installing netifd (2026.02.26~cbb83a18-r1)
( 33/186) Installing openwrt-keyring (2025.12.10~f0670054-r1)
( 34/186) Installing libjson-script20260213 (2026.06.19~7dd12784-r1)
( 35/186) Installing procd (2026.03.13~58eb263d-r1)
( 36/186) Installing procd-seccomp (2026.03.13~58eb263d-r1)
( 37/186) Installing usign (2025.10.03~c4c72b1b-r1)
( 38/186) Installing base-files (1711~f5dae5ece4)
( 39/186) Installing libltdl7 (2.5.4-r1)
( 40/186) Installing libpthread (1.2.5-r5)
( 41/186) Installing collectd (5.12.0-r56)
( 42/186) Installing libsysfs2 (2.1.0-r4)
( 43/186) Installing sysfsutils (2.1.0-r4)
( 44/186) Installing libsensors5 (3.6.2-r6)
( 45/186) Installing lm-sensors (3.6.2-r6)
( 46/186) Installing collectd-mod-sensors (5.12.0-r56)
( 47/186) Installing dnsmasq (2.93-r1)
( 48/186) Installing dropbear (2025.89-r3)
( 49/186) Installing kernel (6.12.94~5a6c1f71be683ae9980b15d3ce73e24d-r1)
( 50/186) Installing kmod-crypto-hash (6.12.94-r1)
( 51/186) Installing kmod-crypto-crc32c (6.12.94-r1)
( 52/186) Installing kmod-lib-crc32c (6.12.94-r1)
( 53/186) Installing kmod-nf-conntrack (6.12.94-r1)
( 54/186) Installing kmod-nf-conntrack6 (6.12.94-r1)
( 55/186) Installing kmod-nf-log (6.12.94-r1)
( 56/186) Installing kmod-nf-log6 (6.12.94-r1)
( 57/186) Installing kmod-nf-nat (6.12.94-r1)
( 58/186) Installing kmod-nf-reject (6.12.94-r1)
( 59/186) Installing kmod-nf-reject6 (6.12.94-r1)
( 60/186) Installing kmod-nfnetlink (6.12.94-r1)
( 61/186) Installing kmod-nft-core (6.12.94-r1)
( 62/186) Installing kmod-nft-fib (6.12.94-r1)
( 63/186) Installing kmod-nft-nat (6.12.94-r1)
( 64/186) Installing kmod-nf-flow (6.12.94-r1)
( 65/186) Installing kmod-nft-offload (6.12.94-r1)
( 66/186) Installing jansson4 (2.14.1-r1)
( 67/186) Installing libmnl0 (1.0.5-r1)
( 68/186) Installing libnftnl11 (1.3.1-r1)
( 69/186) Installing nftables-json (1.1.6-r2)
( 70/186) Installing firewall4 (2025.03.17~b6e51575-r2)
( 71/186) Installing fit-check-sign (2025.10-r2)
( 72/186) Installing fitblk (2)
( 73/186) Installing eip197-mini-firmware (20260221-r1)
( 74/186) Installing kmod-crypto-null (6.12.94-r1)
( 75/186) Installing kmod-crypto-aead (6.12.94-r1)
( 76/186) Installing kmod-crypto-manager (6.12.94-r1)
( 77/186) Installing kmod-crypto-authenc (6.12.94-r1)
( 78/186) Installing kmod-crypto-des (6.12.94-r1)
( 79/186) Installing kmod-crypto-hmac (6.12.94-r1)
( 80/186) Installing kmod-crypto-md5 (6.12.94-r1)
( 81/186) Installing kmod-crypto-sha1 (6.12.94-r1)
( 82/186) Installing kmod-crypto-sha256 (6.12.94-r1)
( 83/186) Installing kmod-crypto-sha512 (6.12.94-r1)
( 84/186) Installing kmod-crypto-hw-safexcel (6.12.94-r1)
( 85/186) Installing kmod-gpio-button-hotplug (6.12.94-r5)
( 86/186) Installing kmod-leds-gpio (6.12.94-r1)
( 87/186) Installing kmod-i2c-core (6.12.94-r1)
( 88/186) Installing kmod-hwmon-core (6.12.94-r1)
( 89/186) Installing hostapd-common (2025.08.26~ca266cc2-r1)
( 90/186) Installing iw (6.17-r1)
( 91/186) Installing ucode-mod-digest (2026.01.16~85922056-r1)
( 92/186) Installing ucode-mod-nl80211 (2026.01.16~85922056-r1)
( 93/186) Installing ucode-mod-rtnl (2026.01.16~85922056-r1)
( 94/186) Installing wifi-scripts (1.0-r1)
( 95/186) Installing wireless-regdb (2026.05.30-r1)
( 96/186) Installing kmod-cfg80211 (6.12.94.6.18.26-r1)
( 97/186) Installing kmod-crypto-sha3 (6.12.94-r1)
( 98/186) Installing kmod-crypto-rng (6.12.94-r1)
( 99/186) Installing kmod-crypto-geniv (6.12.94-r1)
(100/186) Installing kmod-crypto-seqiv (6.12.94-r1)
(101/186) Installing kmod-crypto-ctr (6.12.94-r1)
(102/186) Installing kmod-crypto-ccm (6.12.94-r1)
(103/186) Installing kmod-crypto-cmac (6.12.94-r1)
(104/186) Installing kmod-crypto-gf128 (6.12.94-r1)
(105/186) Installing kmod-crypto-ghash (6.12.94-r1)
(106/186) Installing kmod-crypto-gcm (6.12.94-r1)
(107/186) Installing kmod-mac80211 (6.12.94.6.18.26-r1)
(108/186) Installing kmod-mt76-core (6.12.94.2026.03.19~39c960c3-r2)
(109/186) Installing kmod-mt76-connac (6.12.94.2026.03.19~39c960c3-r2)
(110/186) Installing kmod-thermal (6.12.94-r1)
(111/186) Installing kmod-mt7915e (6.12.94.2026.03.19~39c960c3-r2)
(112/186) Installing kmod-mt7986-firmware (6.12.94.2026.03.19~39c960c3-r2)
(113/186) Installing kmod-nls-base (6.12.94-r1)
(114/186) Installing kmod-usb-common (6.12.94-r1)
(115/186) Installing kmod-usb-core (6.12.94-r1)
(116/186) Installing kmod-usb-xhci-hcd (6.12.94-r1)
(117/186) Installing kmod-usb-xhci-mtk (6.12.94-r1)
(118/186) Installing kmod-usb3 (6.12.94-r1)
(119/186) Installing libustream-mbedtls20201210 (2026.03.01~99f1c0db-r1)
(120/186) Installing logd (2025.10.30~6f78fa49-r1)
(121/186) Installing cgi-io (2026.06.28~7314451c-r1)
(122/186) Installing liblucihttp0 (2023.03.15~9b5b683f-r1)
(123/186) Installing liblucihttp-ucode (2023.03.15~9b5b683f-r1)
(124/186) Installing rpcd (2026.06.04~28faf640-r1)
(125/186) Installing rpcd-mod-file (2026.06.04~28faf640-r1)
(126/186) Installing rpcd-mod-luci (20240305-r1)
(127/186) Installing rpcd-mod-ucode (2026.06.04~28faf640-r1)
(128/186) Installing ucode-mod-html (1)
(129/186) Installing ucode-mod-log (2026.01.16~85922056-r1)
(130/186) Installing ucode-mod-math (2026.01.16~85922056-r1)
(131/186) Installing luci-base (26.180.75667~128a781)
(132/186) Installing luci-app-package-manager (26.180.75667~128a781)
(133/186) Installing luci-app-firewall (26.180.75667~128a781)
(134/186) Installing luci-lib-uqr (26.180.75667~128a781)
(135/186) Installing libiwinfo-data (2026.01.14~f5dd57a8-r1)
(136/186) Installing libiwinfo20230701 (2026.01.14~f5dd57a8-r1)
(137/186) Installing rpcd-mod-iwinfo (2026.06.04~28faf640-r1)
(138/186) Installing luci-mod-network (26.180.75667~128a781)
(139/186) Installing luci-mod-status (26.180.75667~128a781)
(140/186) Installing luci-mod-system (26.180.75667~128a781)
(141/186) Installing luci-mod-admin-full (26.180.75667~128a781)
(142/186) Installing luci-proto-ipv6 (26.180.75667~128a781)
(143/186) Installing luci-proto-ppp (26.180.75667~128a781)
(144/186) Installing luci-theme-bootstrap (26.180.75667~128a781)
(145/186) Installing rpcd-mod-rrdns (20170710)
(146/186) Installing uhttpd (2026.06.16~7b1bec45-r1)
(147/186) Installing uhttpd-mod-ubus (2026.06.16~7b1bec45-r1)
(148/186) Installing luci-light (26.180.75667~128a781)
(149/186) Installing luci (26.180.75667~128a781)
(150/186) Installing rpcd-mod-rpcsys (2026.06.04~28faf640-r1)
(151/186) Installing attendedsysupgrade-common (10)
(152/186) Installing luci-app-attendedsysupgrade (26.180.75667~128a781)
(153/186) Installing collectd-mod-cpu (5.12.0-r56)
(154/186) Installing collectd-mod-interface (5.12.0-r56)
(155/186) Installing collectd-mod-iwinfo (5.12.0-r56)
(156/186) Installing collectd-mod-load (5.12.0-r56)
(157/186) Installing collectd-mod-memory (5.12.0-r56)
(158/186) Installing collectd-mod-network (5.12.0-r56)
(159/186) Installing librrd1 (1.0.50-r7)
(160/186) Installing collectd-mod-rrdtool (5.12.0-r56)
(161/186) Installing rrdtool1 (1.0.50-r7)
(162/186) Installing luci-app-statistics (26.180.75667~128a781)
(163/186) Installing tinyproxy (1.11.1-r3)
(164/186) Installing luci-app-tinyproxy (26.180.75667~128a781)
(165/186) Installing usteer (2025.10.04~1d6524c6-r1)
(166/186) Installing luci-app-usteer (26.180.75667~128a781)
(167/186) Installing px5g-mbedtls (11)
(168/186) Installing luci-ssl (26.180.75667~128a781)
(169/186) Installing mt7986-wo-firmware (20260221-r1)
(170/186) Installing mtd (27)
(171/186) Installing odhcp6c (2026.06.20~07d324ee-r1)
(172/186) Installing odhcpd-ipv6only (2026.06.29~5d7be43f-r1)
(173/186) Installing kmod-lib-crc-ccitt (6.12.94-r1)
(174/186) Installing kmod-slhc (6.12.94-r1)
(175/186) Installing kmod-ppp (6.12.94-r1)
(176/186) Installing ppp (2.5.2-r3)
(177/186) Installing kmod-pppox (6.12.94-r1)
(178/186) Installing kmod-pppoe (6.12.94-r1)
(179/186) Installing ppp-mod-pppoe (2.5.2-r3)
(180/186) Installing procd-ujail (2026.03.13~58eb263d-r1)
(181/186) Installing uboot-envtools (2025.10-r2)
(182/186) Installing uci (2025.12.02~66127cd7-r1)
(183/186) Installing getrandom (2025.10.30~6f78fa49-r1)
(184/186) Installing urandom-seed (3)
(185/186) Installing urngd (2025.10.03~f17e33d9-r1)
(186/186) Installing wpad-mbedtls (2025.08.26~ca266cc2-r1)
OK: 56.3 MiB in 186 packages

Finalizing root filesystem...
add alternative: /usr/bin/ssh-keygen -> /usr/sbin/dropbear
add alternative: /usr/bin/scp -> /usr/sbin/dropbear
add alternative: /usr/bin/ssh -> /usr/sbin/dropbear
add alternative: /sbin/logread -> /usr/libexec/logread-ubox
add alternative: /sbin/rmmod -> /sbin/kmodloader
add alternative: /sbin/insmod -> /sbin/kmodloader
add alternative: /sbin/lsmod -> /sbin/kmodloader
add alternative: /sbin/modinfo -> /sbin/kmodloader
add alternative: /sbin/modprobe -> /sbin/kmodloader
add alternative: /usr/bin/wget -> /bin/uclient-fetch
Enabling adguardhome
Enabling boot
Enabling bootcount
Enabling collectd
Enabling cron
Enabling dnsmasq
Enabling done
Enabling dropbear
Enabling firewall
Enabling gpio_switch
Enabling led
Enabling lm-sensors
Enabling log
Enabling luci_statistics
Enabling network
Enabling odhcpd
Enabling packet_steering
Enabling radius
Enabling rpcd
Enabling sysctl
Enabling sysfixtime
Enabling sysfsutils
Enabling sysntpd
Enabling system
Enabling tinyproxy
Enabling ubihealthd
Enabling ucitrack
Enabling uhttpd
Enabling umount
Enabling urandom_seed
Enabling urngd
Enabling usteer
Enabling wpad

Building images...
Parallel mksquashfs: Using 16 processors
Creating 4.0 filesystem on /builder/build_dir/target-aarch64_cortex-a53_musl/linux-mediatek_filogic/root.squashfs, block size 262144.

[|                                                             ]    0/1286   0%
[=============================================================|] 1353/1353 100%

Exportable Squashfs 4.0 filesystem, xz compressed, data block size 262144
	compressed data, compressed metadata, compressed fragments,
	no xattrs, compressed ids
	duplicates are removed
Filesystem size 14481.46 Kbytes (14.14 Mbytes)
	24.99% of uncompressed filesystem size (57938.13 Kbytes)
Inode table size 11122 bytes (10.86 Kbytes)
	22.13% of uncompressed inode table size (50268 bytes)
Directory table size 15024 bytes (14.67 Kbytes)
	48.14% of uncompressed directory table size (31212 bytes)
Number of duplicate files found 21
Number of inodes 1498
Number of files 1119
Number of fragments 42
Number of symbolic links 235
Number of device nodes 1
Number of fifo nodes 0
Number of socket nodes 0
Number of directories 143
Number of hard-links 0
Number of ids (unique uids + gids) 1
Number of uids 1
	unknown (0)
Number of gids 1
	unknown (0)
FIT description: ARM64 OpenWrt FIT (Flattened Image Tree)
Created:         Mon Jun 29 12:59:20 2026
 Image 0 (kernel-1)
  Description:  ARM64 OpenWrt Linux-6.12.94
  Created:      Mon Jun 29 12:59:20 2026
  Type:         Kernel Image
  Compression:  gzip compressed
  Data Size:    5882549 Bytes = 5744.68 KiB = 5.61 MiB
  Architecture: AArch64
  OS:           Linux
  Load Address: 0x48000000
  Entry Point:  0x48000000
  Hash algo:    crc32
  Hash value:   b753cd8c
  Hash algo:    sha1
  Hash value:   c45ebefb94fe35914f4a4f8b277e442d27b32a2c
 Image 1 (fdt-1)
  Description:  ARM64 OpenWrt tplink_tl-xdr6086 device tree blob
  Created:      Mon Jun 29 12:59:20 2026
  Type:         Flat Device Tree
  Compression:  uncompressed
  Data Size:    21452 Bytes = 20.95 KiB = 0.02 MiB
  Architecture: AArch64
  Hash algo:    crc32
  Hash value:   0346f54e
  Hash algo:    sha1
  Hash value:   ce7dd4b8f7861e7c28c2e7144806c2362f9bd2bd
 Image 2 (rootfs-1)
  Description:  ARM64 OpenWrt tplink_tl-xdr6086 rootfs
  Created:      Mon Jun 29 12:59:20 2026
  Type:         Filesystem Image
  Compression:  uncompressed
  Data Size:    14831616 Bytes = 14484.00 KiB = 14.14 MiB
  Hash algo:    crc32
  Hash value:   1da970db
  Hash algo:    sha1
  Hash value:   1330309df16fa2cda3589e60bd2872f3380e960f
 Default Configuration: 'config-1'
 Configuration 0 (config-1)
  Description:  OpenWrt tplink_tl-xdr6086
  Kernel:       kernel-1
  FDT:          fdt-1
  Loadables:    rootfs-1

Calculating checksums...

are you sure it was sysupgrade that failed, not the image build process ?

I cannot say where is the problem, I am a newbie in firmware refreshing activities. However, I can download the image (openwrt-25.12.5-3619fcdf350e-mediatek-filogic-tplink_tl-xdr6086-squashfs-sysupgrade.itb), and successfully upload in luci, and start the refresh, but after reboot, the router is still in old version, no error message in the process.

I chatted with gemini on this issue. There might be some relevant clues. I found a commit mediatek: filogic: switch TP-LINK XDR series to fitblk Instead of using the deprecated FIT partition parser, use the new fitblk driver instead. The fitblk is not installed on my current 24.10.4 version. I am not sure whether this change will cause the failure of sysupgrade. Any advice on it?

missing fitblk was an issue with other devices during upgrades on 24.10, installing it def won't hurt.
for once, AI might actually be correct ,)

Yeah, missing fitblk definitely results in those symptoms: sysupgrade runs "without error" (there is an error, sysupgrade just doesn't report it) and reboots, but nothing was actually upgraded. Do opkg update && opkg install fitblk, then try again...

This is the right solution. Thank you very much.