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PENDING Problems upgrading Win11 23H2 --> 25H2 PCs using SCCM OSD

SirTimbit

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Hi there! Just curious if others are experiencing the same problems I have in trying to upgrade client PCs from Win11 23H2 to 25H2.
Most of our staff PCs are currently on Win11 Enterprise 23H2, and I'm trying to use an SCCM OSD Upgrade TS to get them up to 25H2. We're currently running ConfigMgr 2509.
It feels like my success rate is half! The machines are all pretty much the same and I don't think it's a problem with the package, given that clearly a good portion of the PCs are upgrading OK.
The client PCs will receive the upgrade TS and start upgrading. From what I've seen, the upgrade fails during the offline portion. I downloaded SetupDiag from Microsoft and the errors are typically:
Error: SetupDiag reports rollback failure found.
Last Phase = Safe OS
Last Operation = Offline portion of machine-specific and machine-independent apply operations
Error = 0x8007042B-0x2000D
Then Windows Setup reverts back to 23H2. As for SCCM itself, Software Center will show the 25H2 upgrade as successful, just to annoy me.

Various steps I've tried include running Cleanmgr, DISM /online /cleanup-image /checkhealth, chkdsk c: /scan, sfc /scannow, windows update reset steps, ensuring our third party AV/EDR software is disabled.
Sometimes this works, but more often than not it seems it doesn't.
I've been Googling away at this for a while and it sounds like others have experienced problems going from 23H2 to 25H2 specifically. See https://techcommunity.microsoft.com...pgrade-fails-in-safe-os--migrate-data/4475743

Now the kicker: what I'm finding a bit odd here is that, if I mount the 25H2 ISO and do a manual upgrade from 23H2 to 25H2, the upgrade completes OK. But this takes longer and requires more manual steps than just kicking off a TS.

The link above suggests Microsoft devs are aware that this may be an issue for 23H2 to 25H2 upgrades but don't have a fix. I haven't found a whole lot of other info on this. I know we used SCCM upgrade TSs to upgrade our fleet of PCs from Win10 to Win11 23H2 a few years ago without much of a problem. We skipped 24H2 as 23H2 was still getting support. With support for 23H2 Enterprise ending this fall however, we've started the upgrades again, only to find it going not so smooth as our previous attempts.
So I'm just trying to get a sense of what others are experiencing in this scenario, or whatever troubleshooting steps I can try. Thanks in advance!
 

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