Resolving Boot Hang After BCM94360CD Wi-Fi Card Installation in Hackintosh

The issue you are encountering, where the Hackintosh boot process hangs after replacing the Wi-Fi card, suggests a conflict or issue within the boot process that is related to the new BCM94360CD card. This card is often favored for Hackintosh builds as it's known for its out-of-the-box compatibility with macOS due to its native support. However, hardware swaps like this can sometimes cause issues that prevent the system from booting properly.

Here's a step-by-step guide to troubleshoot the issue:

Guide Step by Step:

1. Check BIOS Settings:

   • Ensure that the Wi-Fi card is recognized in the BIOS.
   • Disable any settings like "Fast Boot" and ensure that the boot sequence is correct.

2. Reset NVRAM:

   • Boot to your OpenCore or Clover boot menu and reset the NVRAM. This can resolve issues caused by old boot configurations stored in NVRAM.

3. EFI Partition Verification:

   • Verify that the EFI partition on your SSD is intact and correctly formatted as FAT32.
   • Confirm that the cloned EFI directory structure is exactly the same as the one on the USB stick.

4. Correct Kexts and Drivers:

   • Make sure you have the necessary kexts for the new Wi-Fi card. Even though BCM94360CD is supposed to work OOB, it's good to check if there are any conflicting kexts from the previous setup.

5. Rebuild Kernel Cache:

   • Boot from your USB stick and use the terminal to rebuild the kernel cache on your SSD. You can use the command sudo kextcache -i / when booted into your main partition.

6. Bootloader Configuration:

   • Ensure your bootloader configuration does not have any settings specific to the old Intel Wi-Fi card.
   • Check if there are any arguments or settings enabled that might be causing the hang.

7. Examine Boot Logs:

   • Boot in verbose mode to see more detailed logs and identify where the boot process hangs.
   • Look for any error messages that could indicate a driver or kext issue related to the new Wi-Fi card.

8. Test Without Wi-Fi Card:

   • Try booting without the Wi-Fi card installed to see if the system progresses past the hang. If it does, the issue is likely related to the Wi-Fi card or its initialization.

9. Compare Configurations:

   • Compare the config.plist file from your USB stick with the one on your SSD. There might be slight differences causing the issue.

10. Firmware Check:

    • Make sure the Wi-Fi card's firmware is up to date. Sometimes, firmware updates can improve compatibility.

11. Hardware Compatibility:

    • Double-check that the BCM94360CD card is not defective and is seated correctly in the slot.

12. Seek Community Help:

    • If the issue persists, seek assistance from Hackintosh forums or communities, providing them with detailed information about the error and your hardware setup.

Create config.plist:

Creating or modifying a config.plist can be complex and should be done carefully to avoid boot issues. Ensure you're using a plist editor designed for Hackintosh use, like ProperTree, and validate your config.plist against a working one from the Hackintosh community for similar hardware setups.

Conclusion: Swapping hardware in a Hackintosh can lead to boot issues, but they are often resolvable with careful troubleshooting. By following these steps, you should be able to identify the cause of the boot hang and get your system up and running with the new Wi-Fi card. Remember to always back up your current working EFI folder before making changes.