Linsys E4200v1 bricked after updating to r43718 [SOLVED]

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madi123
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PostPosted: Tue Jul 14, 2020 7:27    Post subject: Linsys E4200v1 bricked after updating to r43718 [SOLVED] Reply with quote
Here is the story:

I had BS dd-wrt.v24-30880_NEWD-2_K2.6_mega-nv60k.bin (http://ddwrt.stevejenkins.com/builds/30880/dd-wrt.v24-30880_NEWD-2_K2.6_mega-nv60k.bin) build up and running and decided to update to the latest k2.6 nv60K mega build r43718 from dd-wrt web interface (https://download1.dd-wrt.com/dd-wrtv2/downloads/betas/2020/07-09-2020-r43718/broadcom_K26/dd-wrt.v24-43718_NEWD-2_K2.6_mega-nv60k.bin). I used LAN cable connection and did 30/30/30 reset before the update.

I flashed the router, waited for 2 minutes, did a 30/30/30 reset and... nothing. Router just flashed 3.5 times and then lights go off

Router was still accessible through tftp (https://wiki.dd-wrt.com/wiki/index.php/Tftp_flash), so I've tried to recover through tftp with different trailing mini e4200v1 builds including one suggested here https://wiki.dd-wrt.com/wiki/index.php/Linksys_E4200, but router did not revive. After waitnig for 2 minutes, power cycling and 30/30/30 it just flashes 3 and a half times then lights go off. I've also tried another laptop and cable. I've tried flashing original build dd-wrt.v24-30880_NEWD-2_K2.6_mega-nv60k.bin. After several attempts TFTP said flashing was successful but router was still not coming up after 2 min wait and reboots/resets

I think I've soft bricked the router and according to tftp wiki I have to upload the e4200 OEM firmware but it is to big to get through

If only I can put the original firmware (https://downloads.linksys.com/downloads/firmware/1224665244042/FW_E4200_1.0.06.003_US_20140520_code.bin), but it's size is too big (11.8Mb) and the timing is too short to get it through tftp (tried both app and cmd commands)

Is there anything else that can be done without serial/jtag recovery. Did you have similar issue? Router is quite old, so I don't want invest too much time without further expertise, but any software related help would be much appreciated!

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kernel-panic69
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PostPosted: Tue Jul 14, 2020 7:36    Post subject: Reply with quote
The linksys tftp client or 4.52 32-bit tftpd32 by a.jounin client/server configured for 1024 byte anticipation window. If you absolutely have to, use a static IP address on client. Worst case, a dumb switch between client and router. Ping, put, power. Also, you should've crossed over to K3.x at 35531 and upgraded from there as I have outlined several times recently. You should be able to TFTP recover from a bad flash to 35531, at the very least. The k2.6 builds are broken again, probably not going to be fixed until at least the next release. P.S. you have to use a trailed build with E4200 in the file name or stock firmware to TFTP flash, the mega nv60k files will not flash.
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madi123
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PostPosted: Tue Jul 14, 2020 9:20    Post subject: Reply with quote
I've uploaded the K3X version below:

https://download1.dd-wrt.com/dd-wrtv2/downloads/betas/2018/03-26-2018-r35531/broadcom_K3X/dd-wrt.v24-35531_NEWD-2_K3.x_mega-e4200.bin

tftp linsys client said firmware upload was successful.
Then I waited for couple of minutes and id a 30/30/30 reset. Still nothing happened.

I don't have a switch but it looks like I still can't fit the 9.2MB original 1.0.0 FW I found here https://forum.dd-wrt.com/phpBB2/viewtopic.php?t=86316&postdays=0&postorder=asc&start=615

What helped a bit is holding a reset button for 5 sec while connecting power cord. It helps to initiate the lan connection, but still I can't fit the original OEM firmware (abrupts at approximately ~8Mb since I was able to upload 7.5Mb mega trailing DD-WRT builds).

It feels like it just doesn't accept anything above 8Mb since I also tried on a slower PC with 100mb/s Ethernet and was still able to upload the mega trailing build even if took longer (~8 sec vs 5 sec).

Is there any way to strip/downsize the original firmware? Should I also try tftpd32 with 1024 bytes anticipation window, or may be trying uploading OpenWRT or I need to find switch. I think I'm at the right direction, just need a bit more ideas

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madi123
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Joined: 04 Mar 2008
Posts: 124

PostPosted: Tue Jul 14, 2020 11:11    Post subject: Reply with quote
OK 2 things to devs after I've spent 2 more hours:

1) Why you continue compiling a faulty K2.6 Broadcom firmwares, can't you just stop releasing them for devices you know are not going to work
2) Why you've limited recovery flash size to 8Mb knowing the original e4200v1 linksys firmware is 9Mb in size (v 1.0.0)

Because of 1 and 2 I now have a faulty device and can't recover. I know that responsibility is on me, but you can still fix 1 and 2 above where it is still possible to do so (remove faulty builds at least) .
My overall feedback is that it is really disappointing that I've lost a working piece of hardware(

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kernel-panic69
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PostPosted: Tue Jul 14, 2020 11:31    Post subject: Reply with quote
Serial recovery isn't that difficult, it's just getting the router open to install the pins / hook up. I've had a few of these come through the shop that I never had to use serial on.

https://forum.dd-wrt.com/phpBB2/viewtopic.php?t=290939

https://forum.dd-wrt.com/phpBB2/viewtopic.php?p=693780

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madi123
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PostPosted: Wed Jul 15, 2020 17:50    Post subject: Happy ending story here Reply with quote
All went good with serial recovery process:

Basically it was a 3 step process:

1) Hardware. I needed to get a USB-to-Serial interface, which I didn't have. However, I had an Arduino micro kit (clone example) based on ATmega32u4 5V/16Mhz, which I knew had onboard usb/serial that can be programmed. I've also used an old usb cable, cut it and attached thoroughly 3 wires from both sides for GND-GND, TX-RX, RX-TX (no soldering, no resistors, see pictures and here).

2) Software. I've downloaded an Arduino cc IDE kit to code usb-serial redirection link, tftp2 and PuTTy utilities, an original Linksys e4200v1 firmware (version 1.0.0) and two e4200v1 Broadcom k3x specific DD-WRT firmwares (r35531 and r42954)

3) Process. Except for Arduino sketch coding where i put 115200 instead of 9600 for baud rate, everything else was in line with DD-WRT Serial Recovery wiki

Serial connection params were set 115200,8,1,no parity, no flow control (Arduino & PuTTy)

Oher setup: Windows 10 64Bit, 100 Mbit LAN, Static IP: 192.168.1.10, mask 255.255.255.0, not necessary, but gateway/dns 192.168.1.1

After powering router I finally saw a CFE output on my PuTTy screen (forgot screenshot), it took me just few minutes to complete sub steps below (taken from here or wiki above):

a) Promptly hit enter on putty to get cfe> welcome message, then
cfe>
Code:
nvram erase

b) Run command cfe>
Code:
flash -ctheader : flash1.trx
and used tftp2 to promptly upload the OEM firmware (run twice to catch the window)
c) Typed
Code:
go
and at some point later had to hit enter again, and then waited for ~2 min
d) Uploaded K3X r35531 firmware through Cisco web interface (root/admin default username/password), waited 2 min, then did 30/30/30 reset
e) Uploaded K3X r42954 firmware through web interface, waited another 2 min, then did a 30/30/30 reset (to be safe)

At last I recovered all DD-Wrt settings. Had to format usb drive from ext2 to fat32. Everything else simply worked



IMG_20200715_004725__01.jpg
 Description:
Serial JB2 Wiring (notice huge radiator on CPU)
 Filesize:  321.2 KB
 Viewed:  3611 Time(s)

IMG_20200715_004725__01.jpg



IMG_20200715_004714__01.jpg
 Description:
Arduino Pro micro wiring
 Filesize:  234.68 KB
 Viewed:  3611 Time(s)

IMG_20200715_004714__01.jpg



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kernel-panic69
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PostPosted: Wed Jul 15, 2020 17:58    Post subject: Reply with quote
Thanks for the update. Now you should be able to flash 43028 and 43813 K3x (K4x) and be up to date and have working samba Smile
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madi123
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PostPosted: Wed Jul 15, 2020 19:00    Post subject: Reply with quote
Thanks, oops, should I be aware of any issues with r42954? Samba seems working fine, but I haven't done thorough testing yet. Would be great to know if I really need to update 2 more times because of known issues for e4200?
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kernel-panic69
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PostPosted: Wed Jul 15, 2020 19:24    Post subject: Reply with quote
Samba is a WIP, not sure if you will run into issues. There's just several other things that have been in development along with Samba in the firmware that you are missing out on is all. WebUI stability improved drastically in 43516, for example. If you find 42954 is working good for you, then stay there, but you may find issues that have since been resolved...

But you should've been following build releases to know if there were issues with 42954, anyway Razz

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madi123
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PostPosted: Tue Sep 22, 2020 18:55    Post subject: Reply with quote
Ok, just for all you folks owning e4200v1 and wanting a no bricking path. I've upgraded from R42954 to R43028 no reset, then to R43813 with reset. Finally, to the latest DD-WRT v3.0-r44406 mega (09/18/20) with 30-30-30 reset. All is working fine.

Please read above if you have a firmware earlier than R42954

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madi123
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Posts: 124

PostPosted: Thu Oct 01, 2020 18:13    Post subject: Reply with quote
R44406 was causing random reboots, so I went back to K2.6 build 30880 (Brainslayer). First had to go back to Linksys original FW with 30-30-30 reset.
Finally, I went back to 2014 kinkong 22000++ build, it works faster and proven to be stable.

What I found is that in a setup with 5+ devices with QoS HTB enabled it randomly hangs most of time with 50Mbit/s WAN on any build.

Now I want to see if the oldest suggested stable build with QoS disabled is working fine.

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madi123
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PostPosted: Sun Oct 04, 2020 17:46    Post subject: Reply with quote
I couldn't resolve random hang&reboot problem on my e4200v1, so I went back to stock v1.06. 2 days and no issues. I couldn't find what caused instability
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madi123
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Posts: 124

PostPosted: Tue Oct 06, 2020 18:26    Post subject: Reply with quote
Guess what. This router had random reboots even on stock firmware (internet loss for 1-2 min). I found a pattern that those reboots/hangs usually happen in the early evening which coincide with electricity peak time. My new hypothesis it is related to the AC/DC power supply (12V 2A) instability.

Fortunately my modem uses 12V 2A and the same connector. So I just swaped DC power bricks and will give linksys e4200v1 another try. Fingers crossed.

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