Hi Peter,

thank you very much for your quick response! I have more information on this topic now.

Peter Rossbach wrote:
First your are sure that your wars inside the installation art identical?

Yes I am. Our automated install procedure ensures that.

You stacktraces are strange.
   The cast inside writeSession use only tomcat classes!
Have you change the authorisation and use your own principal implementation ?

No. We did no such changes. I already thought it might have something to do with different Classloaders used by the two tomcats, but I know too little about the Classloaders that tomcat uses to judge this suspicion.

For more help I think do the following steps
a)   update to tomcat 5.5.9
b) install the cluster fix ( The Bug Database http://issues.apache.org/bugzilla/show_bug.cgi?id=34389) c) change your Cluster Config from SimpleTcpReplicationManager to DeltaManager
d)   Use fastasyncqueue mode.

We die the same modifications to our testcluster now. Because the configuration files are autogenerated i am sure that the config files are the same except the details that have to be different (like machine names etc.). Besides that we have exactly the same software (webapp) running on the testcluster.

The interesting part is that we do not see these ClassCastExceptions in the testcluster?

I originally thought that it might be that we got something wrong with the tomcat set-up and i've reinstalled tomcat 5.5.4 plus jdk1.4 patch on the production machines but this did not help.

We also noticed that these class cast exceptions do not depend on the numbers of sessions we have. They are roughly constant at roughly 2 such exceptions per minute, even during the night where our session count drops to basically 0.

We currently cannot upgrade to tomcat 5.5.9 because of our upgrade policy to only upgrade software when it was extensively tested in our test environment.

Via Google I only found one post with a remotely similar problem:
http://www.junlu.com/msg/65888.html
otherwise I have no more Ideas on how to continue from here.

Do you see any other way how to analyse and debug this problem?

Thank you very much!
--
Christian Schuhegger
http://www.el-chef.de/


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