macOS 15.4 update failed on external disk

I've got a maybe somewhat odd setup here. MacBook Pro M2 Max with macOS Sequoia 15.4 running on the internal SSD (APFS, encrypted). In addition I have an external NVMe SSD (Samsung T7) where I've also installed macOS Sequoia to be used as StartUp-Disk if need be. With that setup I keep my private and my corporate macOS installations physically separated. "Just" using the same MacBook Pro to run them.


Now I tried to apply the latest update from macOS 15.3 to 15.4 on my external SSD. The update shows, the external disk is set as StartUp Disk and the update process starts. It looks like it does the update with multiple reboots and all. But after it's finished and log in to the macOS it still shows the update 15.4 as available. There were no apparent errors during the update process. But I noticed that wen I log in after the update the system complains that it was improperly shut down and whether it should report that.


Any idea how to debug this? The update worked just fine on the internal SSD without any issue.


MacBook Pro 14″, macOS 15.4

Posted on Apr 1, 2025 5:54 AM

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Posted on Apr 1, 2025 9:59 AM

I’ve had the same problem, except mine is with two different volumes on the internal SSD on my M1 Macbook Pro. My work side updated absolutely fine, but I was unable to update my personal side - it rebooted in a similar way to yours, but then just had an “We ran into a problem” style prompt with the option to report.


As there are a fair few vulnerabilities addressed with this update and I had not rebuilt my personal volume since I got the device, I thought I’d try installing from scratch but I’m hitting the same problem with just trying to install the OS on the separate volume, it doesn’t complete successfully and now I’m stuck with just my work volume.


Planning on doing some more troubleshooting at the weekend when I have some more time, but this isn’t ideal.

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Apr 2, 2025 12:32 AM in response to crazyl999

just out of curiosity... is your personal volume using a case-sensitive filesystem? Because I just recalled that this is the one major difference I have. My internal SSD is just normal APFS, not case sensitive. The external SSD is APFS with case-sensitive filesystem. Dunno if that could be the issue.

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Apr 2, 2025 8:17 AM in response to Falko Zurell

Ditto, it didn’t work for me either. I’ve now gone the nuclear route of wiping the entire drive as I have time machine backups of everything, and would like to get my personal volume fixed. Prior to this I tried a first aid repair via disk utility in the recovery menu as recommended elsewhere but I still am unable to install macOS, either from recovery or USB.


I’ve just had a phone call with apple support who directed me to try wiping the device via the password recovery assistant, and I am currently a reinstallation from recovery which will hopefully be more successful!

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Apr 3, 2025 1:42 AM in response to crazyl999

Hi,

I have similar problem on my 14" MacBook Pro M1 Max 2021...

Error message with "panic" message after upgrade to latest Sequoia. So I decided to do full recovery to only available Sequoia.

Recovery started normally, restarts automatically and after reboot it displays dialog to select startup drive. When I select Macintosh HD it says that system must be reinstalled.

I tried erase disk, erase Mac, installation on external SSD with the same result.


Apple support told me that only solution is diagnostic on service center. But I don't think my HW is faulty. It worked fine until latest Sequoia update.


Do anybody make any progress with this issue please? Do you have any information from Apple about it. Do they some inquiries regarding this behaviour?


Thanks

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Apr 3, 2025 3:06 AM in response to Falko Zurell

Falko Zurell wrote:

I've got a maybe somewhat odd setup here. MacBook Pro M2 Max with macOS Sequoia 15.4 running on the internal SSD (APFS, encrypted). In addition I have an external NVMe SSD (Samsung T7) where I've also installed macOS Sequoia to be used as StartUp-Disk if need be. With that setup I keep my private and my corporate macOS installations physically separated. "Just" using the same MacBook Pro to run them.

Now I tried to apply the latest update from macOS 15.3 to 15.4 on my external SSD. The update shows, the external disk is set as StartUp Disk and the update process starts. It looks like it does the update with multiple reboots and all. But after it's finished and log in to the macOS it still shows the update 15.4 as available. There were no apparent errors during the update process. But I noticed that wen I log in after the update the system complains that it was improperly shut down and whether it should report that.

Any idea how to debug this? The update worked just fine on the internal SSD without any issue.


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Apr 3, 2025 11:14 AM in response to ameenjuz

M1 Mac mini. Lost a tb of external drive o was running os off for 3 years. Today I got 15.3.1 installed. Same thing happens on 15.3.2 I beleive. 15.4 I have attempted several different things, and still starts up saying is restarted error. I’m not installing on the onboard drive till there’s a fix. Ordered me another ssd so I have one try try updates first in the future. Set my work back a few days.

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macOS 15.4 update failed on external disk

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