k8s-upgrade: reconcile kubeadm-config OIDC drift that crash-looped the v1.35 apiserver upgrade
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Last night's autonomous 1.34->1.35 run reached the master control-plane phase
for the first time (preflight passed, etcd snapshot taken, etcd upgraded), then
the kube-apiserver upgrade to v1.35.6 crash-looped and kubeadm auto-rolled-back
to 1.34.9. The cluster stayed healthy but the master was left cordoned and the
chain wedged on in_flight.

Root cause: kubeadm upgrade regenerates the apiserver static-pod manifest from
the kubeadm-config ConfigMap. apiserver auth was switched on 2026-06-19 to a
structured multi-issuer --authentication-config (kubectl + dashboard SSO), but
kubeadm-config still carried the legacy single-issuer --oidc-* extraArgs, so the
regenerated manifest reverted structured auth and the new apiserver crash-looped.
Proven via `kubeadm upgrade diff`. The existing post-upgrade OIDC restore step
never ran because the upgrade itself never succeeded.

Fix:
- rbac/apiserver-oidc.tf: the remote script now also reconciles kubeadm-config
  (kubeadm init phase upload-config: drop --oidc-*, add --authentication-config)
  so a future kubeadm upgrade regenerates a correct manifest. Delivered to the
  cluster via the apiserver-oidc-restore ConfigMap the chain re-runs (CI needs no
  ssh key); trigger deliberately not script-hashed since CI cannot ssh.
- k8s-version-upgrade/upgrade-step.sh: new preflight gate runs `kubeadm upgrade
  diff` and BLOCKS+alerts (never drains the master) if --authentication-config
  would still be dropped.
- Post-mortem + runbook updated.

The live kubeadm-config was reconciled directly on the master and verified
(`kubeadm upgrade diff` now shows only the control-plane image bump), so tonight's
run can complete the 1.34->1.35 upgrade.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>
This commit is contained in:
Viktor Barzin 2026-06-25 14:16:04 +00:00
parent c6bba1da6e
commit 60a1cb9a25
4 changed files with 218 additions and 20 deletions

View file

@ -41,6 +41,7 @@ Job 0 — preflight (pinned: k8s-node1)
├── halt-on-alert (kured-style ignore-list)
├── 24h-quiet baseline (no Ready transitions <24h ago)
├── kubeadm upgrade plan matches target (skipped when master already at target — partial-resume)
├── apiserver-OIDC drift gate: kubeadm upgrade diff must NOT drop --authentication-config (else BLOCK+alert)
├── Push k8s_upgrade_in_flight=1, k8s_upgrade_started_timestamp=$(date +%s)
├── Trigger backup-etcd Job, wait, verify snapshot byte count
├── SSH master: containerd skew fix (if master < workers)
@ -222,22 +223,34 @@ Exposed in K8s via ExternalSecret `k8s-upgrade-creds` in the `k8s-upgrade` names
## Common Operations
### Post-upgrade: apiserver OIDC restore (AUTOMATED by the chain since 2026-06-19)
### apiserver OIDC + kubeadm upgrades (kubeadm-config reconciliation since 2026-06-24)
`kubeadm upgrade apply` **regenerates `/etc/kubernetes/manifests/kube-apiserver.yaml`
and drops the `--authentication-config` flag**, silently disabling apiserver
OIDC (kubectl/kubelogin CLI **and** the web dashboard SSO break — tokens get
401). This used to require a manual re-apply after **every** control-plane bump.
from kubeadm-config**. apiserver auth uses a structured multi-issuer
`--authentication-config` (kubectl + dashboard SSO), but kubeadm-config used to
still carry the legacy single-issuer `--oidc-*` extraArgs — so every upgrade
reverted the flag. On the **1.34→1.35** bump that regenerated apiserver
**crash-looped and stalled the whole upgrade mid-flight** (master cordoned, etcd
already bumped); the post-upgrade restore below never ran because `kubeadm
upgrade apply` itself never returned success. Post-mortem:
`docs/post-mortems/2026-06-24-kubeadm-oidc-drift-apiserver-upgrade-stall.md`.
**Now automated:** the `rbac` stack publishes its OIDC restore script to the
`kube-system/apiserver-oidc-restore` ConfigMap, and the version-upgrade chain's
`phase_master` re-runs it on master immediately after `kubeadm upgrade apply`
(while tigera-operator is still quiesced, so the flag-add apiserver restart can't
crashloop the operator). It's idempotent, health-gates `/livez` with
auto-rollback, and is **non-fatal** — a failure only lags SSO until the next rbac
apply (the version upgrade itself already succeeded). So a chain-driven
control-plane bump no longer breaks SSO. The master phase self-skips when master
is already at target, so this only runs when master was actually upgraded.
**Primary fix (2026-06-24):** `stacks/rbac/modules/rbac/apiserver-oidc.tf` now
**reconciles kubeadm-config** (`kubeadm init phase upload-config kubeadm`, rewriting
`apiServer.extraArgs`: drop `--oidc-*`, add `--authentication-config`) as part of
its remote script. So kubeadm regenerates a **correct** manifest and the apiserver
upgrades with a pure image bump — `kubeadm upgrade diff <target>` shows only the
image change. Zero live impact (the CM is read only during an upgrade).
**Backstops:**
- **Preflight gate 4b** runs `kubeadm upgrade diff` and BLOCKs (k8s_upgrade_blocked=1
→ alert) BEFORE draining the master if `--authentication-config` would still be
dropped — so this can never again drain into a crash.
- The `rbac` stack still publishes its restore script to the
`kube-system/apiserver-oidc-restore` ConfigMap, and `phase_master` re-runs it on
master right after `kubeadm upgrade apply` (idempotent, `/livez`-gated with
auto-rollback, non-fatal) — now redundant belt-and-suspenders that *also*
re-reconciles kubeadm-config. Self-skips when master is already at target.
**Manual fallback** — only for an out-of-band/manual `kubeadm` upgrade, or if the
chain logged `WARN: --authentication-config absent after re-apply`: