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It turns out the return code for OSTaskCreatewName is defined in OSTaskCreate. And error code of 40 mean the task priority is already used.
These are my priorities:

#define USERMAIN_PRIO (55)
#define NTP_TASK_PRIO (54)
#define UDP_TASK_PRIO (53)
#define SNMP_PRIO (52)
#define FTP_TASK_PRIO (51 ...

StartTcpUpdate just calls OSTaskCreatewName, and returns the value returned by OSTaskCreatewName. But the uCosLibrary document doesn't define any return values.

Well, this is embarrassing. It is in my code. It's generated when function StartTcpUpdate returns a non-zero value, which in this case is 40.

At the completion of programming a Nano module using Autoupdate, v2.5, the following message is output on the serial port:

TcpUpdate Error: 40

The module is programmed correctly and runs as expected. I have detected nothing wrong. What does that message mean?

The applications are built with v2.9 ...

Any guidance on how we should proceed?

So there is nothing we can do to correct the problem. Yes, these are brand new modules. We bought these through a distributor, Mouser. Should we go through Mouser to return them, who is fighting us tooth and nail about returning these, or send them direct to Netburner?

Yes, we used the Alternate Boot Monitor to successfully download MOD5441x_FactoryApp_APP.s19 to both modules using the FLA command with MTTTY serial terminal. But the app never ran. The same error messages I put in my previous posts were issued.

Neither module was able to get an IP Address when ...

The modules are plugged into our hardware. Tens of modules are programmed in these test fixtures each week. It's only these two modules that won't program. It is rare that modules fail to program.
In one module it appears that the Alternate Monitor is not entered, based on the terminal output. The ...

Yes, I tried the shorting jumper. It didn't help. I have two modules in this state. Both are new. The serial output of the first one is what I put in my first post. Shorting jumper TP1 during bootup produces the same messages as above. It doesn't appear that the Alternate Boot Monitor is started ...

On a brand new MOD54415-200IR module, when I power it up the serial port spits out:

App Header Failed
No Valid app

App Header Failed

NetBurner MCF5441x SPI Boot Monitor V1.06 Feb 28 2020 18:20:21
HELP for help

Using the serial terminal MTTTY, I uploaded MOD5441x-FactoryApp_APP.s19 (from v2.9.5 ...