Thank you again for helping!
I am absolutely sure that there is nothing wrong with the data. Besides the data we actually use, I already tried using a simple blue marble image split up into 4 parts which also did not work. Also I can create the mosaic with the exact same files on my local computer. When uploading the locally created .properties files I can also finish the import on the server and the resulting layer works perfectly in OpenLayers.

   /home/maps1/test # gdalinfo bm_vdg_0102.tif
   Driver: GTiff/GeoTIFF
   Files: bm_vdg_0102.tif
   Size is 5120, 5120
   Coordinate System is:
   PROJCS["unnamed",
        GEOGCS["WGS 84",
            DATUM["unknown",
                SPHEROID["WGS84",6378137,298.257223563]],
            PRIMEM["Greenwich",0],
            UNIT["degree",0.0174532925199433]],
        PROJECTION["VanDerGrinten"],
        PARAMETER["central_meridian",0],
        PARAMETER["false_easting",0],
        PARAMETER["false_northing",0],
        UNIT["metre",1,
            AUTHORITY["EPSG","9001"]]]
   Origin = (0.000000000000000,0.000000000000000)
   Pixel Size = (5000.000000000000000,-5000.000000000000000)
   Metadata:
      AREA_OR_POINT=Area
      TIFFTAG_DATETIME=2010:11:24 15:25:10
      TIFFTAG_RESOLUTIONUNIT=2 (pixels/inch)
      TIFFTAG_SOFTWARE=Adobe Photoshop CS3 Macintosh
      TIFFTAG_XRESOLUTION=72
      TIFFTAG_YRESOLUTION=72
   Image Structure Metadata:
      COMPRESSION=LZW
      INTERLEAVE=PIXEL
   Corner Coordinates:
   Upper Left  (   0.0000000,   0.0000000) (  0d 0' 0.01"E,  0d 0' 0.01"N)
   Lower Left  (       0.000,-25600000.000) (  0d 0' 0.01"E, 87d20'29.71"S)
   Upper Right (25600000.000,       0.000) (129d46'26.14"W,  0d 0' 0.01"N)
   Lower Right (25600000.000,-25600000.000) ( 40d35'58.76"E, 58d27'13.88"S)
   Center      (12800000.000,-12800000.000) (156d11'44.49"E, 72d57' 5.45"S)
   Band 1 Block=5120x17 Type=Byte, ColorInterp=Red
   Band 2 Block=5120x17 Type=Byte, ColorInterp=Green
   Band 3 Block=5120x17 Type=Byte, ColorInterp=Blue

Size, Coordinate System, Pixel Size, Metadata (except Datetime) and Bands are exactly the same for all 4 files.

I just tried 2.2 (already tried 2.1.3 and 2.1.4 before) but the problem remains. In the meantime I also tried using Jetty instead of Tomcat and I tried using the native JAIs but the error remains the same. I also read the blog post regarding Tomcats JreLeakPreventionListener which causes similar problems, but the solutions did not help either.

Am 9/6/12 2:53 PM, schrieb Carlo Cancellieri:
Simon, this sounds really strange.... now let's investigate on images:1. Are 
all the images at the same resolution? (print relevant information using 
gdalinfo)2. have you tested a newer/different version of geoserver? 2.2 or 2.3?
Cheers,Carlo
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