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Workaround for upgrading from macOS Sonoma 14.3.1 to 14.4

OpenCore Version macOS

About

I've noticed that I could not upgrade from macOS 14.3.1 to 14.4 on 2 of my machines when using Software Update. One was my Gigabyte Z490 workstation, the other one was my Lenovo T490 Laptop. Below is how I solved it.

Symptoms

  • Incremental updates download fine via Software Update
  • The preparation stage works fine as well
  • After rebooting, the installer crashes early
  • Starting the existing macOS install results in what looks and behaves like an installation process, but in the end the system will still be on macOS 14.3.1

I don't have a clue why this happens, but it seems something changed drastically between macOS 13.3.1 and 13.4., that makes it impossible on some systems to upgrade via incremental updates.

Workaround

Option 1: Disable SecureBootModel and Airportitlwm.kext

On my Lenovo T490, disabling SecureBootModel and the beta version of AirPortItlwm.kext in favor of ìtlwn.kext did solve the issue of the macOS Installer crashing early, so disabling troublesome kexts might help to resolve the issue in similar circumstances.

  • Set Misc/Security/SecurebootModel to Disabled
  • Disable AirPortItlwm.kext if you have it
  • Enable itlwm.kext (and install HeliPort App)
  • Save your config and reboot
  • Download the macOS 14.4+ update and install it
  • Disable itlwm.kext and re-enable AirPortItlwm.kext again
  • Re-enable SecureBootModel
  • Safe and reboot

Option 2: Install macOS on a new volume

  • Update OpenCore, drivers and kexts to the latest version
  • Download OpenCore Legacy Patcher
  • Use it to download macOS 14.4+ and create a USB Installer
  • Reboot
  • Run the Installer from the USB flash drive
  • Create a new APFS volume on your SSD/NVME in Disk Utility
  • Install macOS on it – if your EFI and config were working fine prior tp installing 14.4, they should work fine now
  • If you face problems, disable SecureBootModel prior to installing

Post-Install

  • Run the Migration Manager to copy over the data from your previous macOS installation
  • Delete the old 14.3.1 macOS Sonoma Volume
  • Re-Enable SecureBootModel

Previously failed workaround attempts (aka: Don't do this!)

  • Someone suggested to change SecureBootModel and the install macOS over the existing 14.3.1 install. ⚠️ DON'T DO THIS! The system volume will be deleted but the installer will crash when attempting to create a new system volume – so you will be left with the Data partition of the 14.3.1 install only – no bootable OS!
  • In this case, you have to install macOS 14.4 on a new APFS volume
  • Once macOS 14.4 is installe, you can acces the old User Account and Data via Finder, but you cannot use the Migration Assistant to get the data onto your current system: masucksazz
  • In this case you have to copy over all your data manually.

Note

If someone has any clues why upgrading from macOS 14.3.1 is such a pita, let me know! Because comments like "Upgrade worked fine for me" followed by the obligatory oversized screenshots of the "About this Mac" section on Forums are not helping anybody.