Next time you have this issue, try connecting a console to the AP and run the 
following:

ap: fsck flash:
Are you sure you want to fsck "flash:" (could take some time) (y/n)?y
flashfs[0]: ……………
ap: boot

This works for us on the failed to reload properly APs.

From: The EDUCAUSE Wireless Issues Constituent Group Listserv 
[mailto:WIRELESS-LAN@LISTSERV.EDUCAUSE.EDU] On Behalf Of Garret Peirce
Sent: Thursday, January 19, 2017 10:44 AM
To: WIRELESS-LAN@LISTSERV.EDUCAUSE.EDU
Subject: Re: [WIRELESS-LAN] Cisco AP 'flash' bug

Ian, thanks for the response.
To commiserate it does feel that wireless ecosystem has been affected by a 
larger bloom of bugs over the last year or so.
Some of that may be due to enhanced vigilance and our tracking them down to 
root causes, but whatever the case, in aggregate it's a concern here as well.

Another related statistic about this issue.
With ~7000 total APs potentially affected we're seeing an incidence rate below 
1% which although low, it's felt more when you're making fire-fighting trips to 
visit/replace affected APs.


On Thu, Jan 19, 2017 at 10:28 AM, Ian Lyons 
<ily...@rollins.edu<mailto:ily...@rollins.edu>> wrote:
Yes, we own that bug too.  Pretty much we have every bug ..and have been 
patching like madmen since July.

From: The EDUCAUSE Wireless Issues Constituent Group Listserv 
[mailto:WIRELESS-LAN@LISTSERV.EDUCAUSE.EDU<mailto:WIRELESS-LAN@LISTSERV.EDUCAUSE.EDU>]
 On Behalf Of Garret Peirce
Sent: Thursday, January 19, 2017 10:27 AM
To: 
WIRELESS-LAN@LISTSERV.EDUCAUSE.EDU<mailto:WIRELESS-LAN@LISTSERV.EDUCAUSE.EDU>
Subject: [WIRELESS-LAN] Cisco AP 'flash' bug

Over the last few months we've run into/discovered a Cisco bug and I was 
curious if any in this community have been seeing it as well.

In a nutshell, it appears the flash is being corrupted and the AP then enters a 
boot loop or fails to boot at all.    We are apparently seeing a failure rate 
of roughly 10 APs per month.  My engineer's summary is below.

=================

CSCvc74528 description is below, but it fails to take into account that 
occasionally the boot loop doesn't happen and the AP will just crash on boot, 
or fail to boot at all. Working with them to add some things to the description.

"APs go into boot cycle due to corrupt image, do not download new image from WLC
CSCvc74528
Description
Symptom:
APs reboot and when booting back up the image gets corrupted. The AP checks the 
WLC and sees it has the same image in flash and does not download the WLC 
image. The image on the AP is corrupt and therefor continuously reboots into 
the corrupted image.

Conditions:
2702I, 3602I and 3702I APs on a 8540 WLC running 8.2.141.0 or 8.3.102.0 code do 
not download WLC code due to same image on flash.

Bad flash in APs

Workaround:
Format APs via console with new image, holds for a few reboots.



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