Found the problem!



Looking at the processes running at the upgrade, there is

- my root shell, 
  PATH is ok

- /bin/sh -c /usr/bin/pkexec /usr/bin/do-release-upgrade 
--frontend=DIstUpgradeViewGtk3 -d
  PATH is ok


- /usr/bin/python3 /tmp/ubuntu-... --mode=server --frontend=...
  PATH  is broken  :   /usr/local/bin:/usr/bin:/bin:/sbin
  lacks /usr/sbin


and it is definitely the pkexec call.

running

pkexec env

as root shows the broken PATH.


Which finally shows the Problem:   /usr/sbin was missing in the PATH variable 
in /etc/environment.


The update process should *urgently* take care to have a complete PATH.

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https://bugs.launchpad.net/bugs/1544904

Title:
  Updating 15.10 to 16.04 alpha2 failed: subprocess exit status 127

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