I just wanted to close this out. I developed my own procedure for migrading hosts. I removed old DL385 G6 servers and replaced them with DL385 G7 (12 core per socket - awsome). As part of my host upgrades I was also moving from ESX 4.0 to ESXi 4.1. I also moved from a boot from SAN model to boot from local SD card. And I decided to move my management and vmkernel logical ports to a standard switch outside of the 1000V (see step 4)
1) Login to the active VSM and run 'show module". Make note of the module number for the host you are working on. You'll need this later.
2) Move VMs off the host to be upgraded
3) Place host in maint mode
4) Create a new standard virtual switch - assign an unused nic and set upstread switch to trunking.
5) Go to the DVS config on the host and click on "Manage Virtual Adapters". Migrate the service console and vmkernel interface my clicking on "Migrate to Virtual Switch". Use the VSS created in step 4.
6) Go back to the host config in vCenter and find "Manage Physical Adapters" from the distributed switch. Remove all of the uplinks.
7) Go to Home > Inventory > Networking and remove the host from the 1000V. You may see an error stating that a port is in use. If so, double check step 5 and you may need to reload the active vsm. I had to do this because of a stuck port.
8) Remove the host from the cluster.
9) Login to the active VSM and run 'show module'. Verify that the vem is no longer registered.
10) Edit the config and remove the vem # for the module you documented in step 1. The command is 'no vem # (replace # with the number from step 1)'
11) Power off the host - it's done.
Now you can build the new server and os just as if it were never there. I won't go into that detail. The deployment docs have that covered.
Remember to redo your port-channels on the VSM after installing the new host. They are lost when the host of removed from the DVS in vCenter. Also be show to upgrade to the version of 1000v to support your ESX/ESXi version. I had already upgraded to 1.3a.
--Patrick
