Bear with me for one last post on this subject in order to explain how the issue was resolved. The issue did not turn out to be mod_perl-related, so this will be of interest mainly to owners of the Buffalo Linkstation.
So briefly, the underlying cause of the problem was a broken grep distributed with the linkstation. The problem with this grep is that when it is invoked via a symlink as egrep, it does not switch into extended regular expression mode. As a result, expressions like "echo GNU | egrep '(GNU|BFD)'" do not match, and the apache configure script does not recognize GNU ld as being GNU. This causes a cascade of errors with the result that apache won't compile with shared objects.
The solution is to install GNU Grep 2.5. Thanks to the list for pointing me in the right direction (ie away from mod_perl).
Cool, but where the problem was coming from? The httpd's ./configure which was running grep to make config decisions? If so you need to report this as a bug to httpd dev, since configure should check that you have the sufficiently good grep installed. (so in the future others won't get burned by the same problem). Thanks.
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