When I attempt to upgrade my version of PCTeX I receive the following error: "Old file not found. However, a file of the same name was found. No update done since file contents do not match." This problem can be circumvented by uninstalling and reinstalling the previous version, and then applying the upgrade.
Please make sure that the version that you're updating is supported by the patch (i.e. you can't use the 4.2.05 update on a 4.0 version).
When you run the upgrade program there is a "Change Options" button. Click this and choose the "Error File" option, and then click "OK". Run the upgrade and when it fails in the PCTeX directory there will be a file named patch.err which tells what happened.
Note: On some systems if the 4.0 to 4.2 upgrade is run from a CD-ROM it causes some long filenames to become truncated. Please copy the upgrade to your hard disk and run it from there.