Ryan Harris is set to miss next week's Ashes opener, having been ruled out of Australia's final tune-up due to his troublesome knee.
Harris underwent major knee surgery last year, but struggled to get back to his best in the Test series against India.
The 35-year-old was rested from the second half of the Sheffield Shield season, but did a mountain of work in the gym.
Harris then skipped the West Indies tour due to the birth of his first child and arrived in London feeling refreshed, stronger and fitter.
The veteran paceman returned to the Australian XI last week, taking four wickets in the tour game against Kent.
Harris was slated to face Essex this week in Chelmsford, but pulled up sore after bowling 30 overs in his comeback match.
He still had a sore knee on Wednesday, when Australia reached 3-135 at lunch after being sent in by Ravi Bopara.
David Warner fell six runs short of a ton when he was caught at gully in the penultimate over before the meal break.
Thomas Moore was on a hat-trick, making it a morning to forget for Chris Rogers and Michael Clarke.
Rogers was out caught behind for 21, but clearly thought he didn't hit it.
Clarke was out for a golden duck, clipping a ball off his pads straight to Ryan ten Doeschate at leg gully.
Harris was able to roll his arm over prior to day one in Chelmsford.
But given the right-armer has played so little since January, the setback will almost certainly end his hopes of featuring in Cardiff next Wednesday.
Coach Darren Lehmann, speaking after his charges' 255-run win over Kent, noted Harris must be "100 per cent before we make him available for selection".
"Ryan Harris has got to be fully fit," Lehmann said.
"He's got to prove to us he can bowl 20 overs in an innings or roughly about, and make sure he's ready to go.
"If he can do that he certainly comes into consideration."
Harris suggested last week that he was keen to play all five Ashes Tests, but agreed with Lehmann he was short of a gallop.
"As much as I bowled in Brisbane on centre wickets, it's very hard to simulate match intensity," he said.
If Harris is unable to take the field in Wales, Australia will name an unchanged attack for the first clash with England.
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