I had the same issue.
It seems that Juniper fixed this issue in Release 6.2.0r12.There is a hint in the Release Notes:
"587433-Sometimes after OS upgrade, the firewall did not start up because of a certain condition in flash writing mechanism."
I was able to upgrade the devices to 6.2.0r12 sucessfully, so I think this issue has been resolved.
Even an upgrade to 6.3.0r9 was possible.
Steve Puluka BSEET Juniper Ambassador Senior Network Engineer JNCIA-ER JNCIA-EX JNCIS-SEC JNCIP-SEC JNCIS-FWV JNCIS-SSL MCP - Managing Server 2003 MCP - Windows XP Professional MCTS Windows 7 http://puluka.com/home
I upgraded two of three SSG-20 to ssg5ssg20.6.3.0r9.0 without issue. The third one bricked. I applied the latest Loadssg5ssg20v133.d boot loader but it didn't help. I tried all but a couple of the 6.3 versions including the oldest one with no luck. I finally applied version ssg5ssg20.6.2.0r3.0 and the router booted. The the third one was different having a T1 and an ADSL PIM card installed and it is several years older. I tried removing the cards but didn't help. I received the same Data Abort Exception code(1002) as this customer in this thread http://forums.juniper.net/t5/ScreenOS-Firewalls-NOT-SRX/SSG5-Software-Upgrade-To-or-Beyond-6-2-0r4-0...
I'm having the exact same issue with a few of my SSG5 units.
Been trying different releases, seems that anything past 6.2R3 is giving the same crash/restart exception code (1002).
Just tried 6.2R13 because the release notes had something that looked promising... "662589—Firewall experienced core dump and rebooted the system when accessing the Dlog process."
