@chris Can you please more information on how the upgrade is verified to be in- complete ?
This MongoDB replica set was upgraded from 4.0.20 to 4.0.28 patch release version last year and didn’t had any issue reported. Feature Compatibility Version was 4.0 for the replica set on all nodes.
Also, I have done the same upgrade the non-prod environment with 5 nodes (upgrading from 4.0 to 4.2) and didn’t see any issue.
I have cleared all the data files on the node where upgrade was showing error, and tried to restart the node. Now the node shows featureCompatibilityVersion 4.2, does changing this back to 4.0 and restarting the node will make the node join the replica set ?