Saturday, September 5, 2026

Perform a Cisco Hardware RMA

These are some of the critical steps when performing a Cisco Return Material Authorization (RMA). This applies to any Cisco device, i.e. router, switch, firewall, etc. The common RMA FAQ can be found in this link. I broke down the RMA process into these different steps (with the help of AI):

Step 1: Initial Troubleshooting and Cisco TAC Engagement
Step 2: Hardware Replacement 
Step 3: Initial RMA Router Validation 
Step 4: Install the Required Software
Step 5: License File Restoration
Step 6: Main Interface Activation and Generate New SSH Key
Step 7: Restore Router Configuration
Step 8: Validation and Acceptance Testing
Step 9: Return Defective Hardware
 

Step 1: Initial Troubleshooting and Cisco TAC Engagement

1.Raise a Cisco TAC case via the Support Case Manager portal (CCO login required). 

Provide the following information:
  • Detailed problem description
  • Impact assessment and outage details
  • Network topology or Visio diagram (recommended)
  • Device model and serial number
  • Relevant timestamps
 
Attach the following output in the case portal:
  • show log
  • Required show command outputs
  • show tech-support
  • Crash information (if available)

Note: Engage a TAC engineer as early as possible to expedite troubleshooting and RMA approval if required.

2.Before performing any recovery action, ensure all files are backed up. Using an external USB disk is recommend for quick transfer of files.

Backup the following from the reported router, if applicable:

  • IOS-XE image
  • ROMmon firmware
  • startup-config from NVRAM (dir nvram:)
  • License files (show license all)
If the IOS-XE and ROMmon files cannot be recovered, download the matching version from the Cisco Software Download Center (CCO login required).

3.Attempt a device recovery. If the router is unresponsive:

  1. Connect to the router using a console cable.
  2. Coordinate all troubleshooting activities with the assigned TAC engineer.
  3. Perform a hard reboot/power cycle
  4. Monitor/capture the entire boot sequence from console.

Verify:

  • ROMmon accessibility
  • IOS-XE boot progress
  • Hardware diagnostics
  • Crash messages or boot failures 

4.Request Cisco TAC to initiate an RMA if troubleshooting and recovery efforts are unsuccessful:

  1. Confirm:
    • Hardware part number
    • Service contract entitlement
    • Shipping address
    • Delivery priority

Important: Cisco RMA shipment typically don't include:

  • Power supplies
  • Rack mounting ears/kits
  • Existing SFP/GBIC modules


Step 2: Hardware Replacement 

5.Once the RMA replacement router arrives, shut down the failed device:

  1. Power off the faulty router.
  2. Label all connected cables:
    • Power cables
    • RJ45 Ethernet cables
    • Fiber cables
  3. Document:
    • Interface-to-cable mapping
    • Installed SFPs/GBICs
    • Rack position/slot

Remove hardware:

  1. Remove power supplies.
  2. Remove SFPs/GBICs.
  3. Remove rack mounting ears.
  4. Unmount the router from the rack.

 

6.Install the RMA Router:

  1. Transfer the following components to the RMA replacement router:
    • Power supplies
    • Rack mounting ears
    • SFPs/GBICs
  2. Mount the RMA router in the rack.
  3. Reconnect:
    • Power cables
    • RJ45 cables
    • Fiber connections
  4. Apply sticker labels to the front and rear of the chassis. 

 

Step 3: Initial RMA Router Validation 

7.Verify base hardware info on the RMA router and monitor its bootup via console. Execute the following commands:

show inventory
show version
show platform
show license all
show run

Verify:

  • Correct hardware model
  • Correct memory size
  • Module detection
  • Chassis serial number
  • License status 


Step 4: Install the Required Software

8.Transfer the IOS-XE and ROMmon files from USB to the RMA router bootflash. 

copy usb0:asrxx-rommon.16xx.pkg bootflash:

copy 
usb0:asrxx-universalk9.16.xx.SPA.bin bootflash:

dir bootflash:

 

Verify the MD5 hash and compare it from the Cisco Software Center website. 

#verify /md5 asrxx-rommon.16xx.pkg

 #verify /md5 asrxx-universalk9.16.xx.SPA.bin

 

9. Perform the RMA router upgrade. Start with the ROMmon firmware upgrade first.


#upgrade rom-monitor filename bootflash:asrxx-rommon.16xx.pkg  all    

reload

show platform



Perform the main IOS-XE upgrade next.

configure terminal

no boot system

boot system flash bootflash:asrxx-universalk9.16.xx.SPA.bin   // TARGET IOS-XE
boot system flash bootflash:asr1001x-universalk9.03.12.xx.bin   // DEFAULT IOS-XE IN RMA 

write memory

show run | inc boot

reload


Phase 5: License File Restoration 


9. If the router is using a Traditional license (non Smart License), re-host or transfer the license file to the RMA router. Contact TAC License team to manually assist and email the Traditional license file. 


#show license udi   !! GIVE TAC LICENSE TEAM THE UDI SERIAL NUMBER

#copy usb0:/JAD23xx.lic bootflash:

#license install bootflash:JAD23xx.lic 

show version

show license all


Phase 6: Main Interface Activation and Generate a new SSH Key

10. Enable main physical interfaces that have the attached SFP and RJ45/fiber cables. Don't save the config at this stage yet.

configure terminal 

interface TenGigabitEthernet0/0/0
 no shutdown

interface GigabitEthernet0/0/1
 no shutdown

interface GigabitEthernet0
 no shutdown


 

10. To prevent router lock out, generate a new SSH key and temporary enable Telnet under the VTY lines. You can disable Telnet once remote SSH/AAA is working.

configure terminal  

ip domain name local.com

crypto key generate rsa modulus 2048
 

line vty 0 4

transport input all

 

Phase 7: Restore Router Configuration

11.Copy the startup-config (from old router) via USB to running-config (RMA router).

#copy usb0:startup-config-new running-config

 

Phase 8: Validation and Acceptance Testing

12.Perform RMA router validation and save config.

show inventory

show version

show platform

show ip interface brief

show ip bgp summary

write memory



13. You'll also need to re-configure SNMP and re-poll the RMA router in your NMS server.

configure terminal 

no snmp-server 

snmp-server group <GROUP> v3 auth read <VIEW> access <ACL>


snmp-server user <USER> <GROUP> v3 auth sha <PW>
snmp-server view <VIEW> internet included
snmp-server view <VIEW> system included
snmp-server view <VIEW> interfaces included

snmp-server location <DEVICE LOCATION>
snmp-server contact <ADMIN CONTACT>

write memory

 

Phase 9: Return Defective Hardware

14. Put the faulty Cisco router using the same box that was sent. Use the Cisco POWR portal to arrange the courier pickup. Also ask the courier to print and apply the shipping label in the box.

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