k8s-upgrade: reclaim+auto-prune kubeadm /etc/kubernetes/tmp leak; correct crash root cause to etcd IO (not OIDC)
Digging into "why did the apiserver crash" disproved the earlier OIDC explanation. An isolated v1.35.6 apiserver repro with authentik reachable initialises OIDC cleanly (oidc.go:313, no error) and runs fine — so the --authentication-config -> --oidc-* revert is NOT what crashed it. etcd's surviving crash-window log is the real cause: 1180 "apply request took too long" warnings in 16 min, individual applies up to 4.3s (healthy <100ms) right as kubeadm tried to bring up the new apiserver. That's etcd IO starvation on the shared sdc HDD (beads code-oflt). A big contributor + the reason master root fs sat at 73%: kubeadm dumps a full ~400MB etcd DB backup into /etc/kubernetes/tmp/kubeadm-backup-etcd-<ts>/ before every etcd upgrade and never cleans it up — 145 dirs / 28GB had accumulated, driving image-GC churn and extra write-IO onto etcd's spindle. Reclaimed live (73% -> 23%) and added a preflight prune (>3 days) so it can't re-accumulate. Also corrected the OIDC handling: the kubeadm-config drift is real but only breaks dashboard/kubectl SSO AFTER a successful upgrade (recoverable via the chain's restore.sh + the kubeadm-config reconciliation) — it does not crash the apiserver. So the preflight check is now an ALERT, not a block (was added on the wrong hypothesis). Post-mortem, runbook, and apiserver-oidc.tf header corrected. Per Viktor: reclaim the disk and automate so the manual cleanup never recurs; the durable IO fix remains code-oflt (etcd off the shared HDD). Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>
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4 changed files with 112 additions and 87 deletions
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@ -41,7 +41,8 @@ Job 0 — preflight (pinned: k8s-node1)
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├── halt-on-alert (kured-style ignore-list)
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├── 24h-quiet baseline (no Ready transitions <24h ago)
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├── kubeadm upgrade plan matches target (skipped when master already at target — partial-resume)
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├── apiserver-OIDC drift gate: kubeadm upgrade diff must NOT drop --authentication-config (else BLOCK+alert)
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├── apiserver-OIDC drift check: kubeadm upgrade diff drops --authentication-config? → Slack WARN (recoverable; not a block)
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├── reclaim kubeadm scratch: prune /etc/kubernetes/tmp/kubeadm-backup-* >3d on master (kubeadm leaks ~400MB etcd-db backups)
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├── Push k8s_upgrade_in_flight=1, k8s_upgrade_started_timestamp=$(date +%s)
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├── Trigger backup-etcd Job, wait, verify snapshot byte count
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├── SSH master: containerd skew fix (if master < workers)
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@ -229,10 +230,10 @@ Exposed in K8s via ExternalSecret `k8s-upgrade-creds` in the `k8s-upgrade` names
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from kubeadm-config**. apiserver auth uses a structured multi-issuer
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`--authentication-config` (kubectl + dashboard SSO), but kubeadm-config used to
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still carry the legacy single-issuer `--oidc-*` extraArgs — so every upgrade
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reverted the flag. On the **1.34→1.35** bump that regenerated apiserver
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**crash-looped and stalled the whole upgrade mid-flight** (master cordoned, etcd
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already bumped); the post-upgrade restore below never ran because `kubeadm
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upgrade apply` itself never returned success. Post-mortem:
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reverted the flag, **silently breaking SSO after the upgrade** (the apiserver does
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NOT crash on this — verified by isolated repro; it's recoverable via the restore
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script below). NB: the **1.34→1.35 stall on 2026-06-24 was a *separate* issue —
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etcd IO starvation**, not this drift; post-mortem:
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`docs/post-mortems/2026-06-24-kubeadm-oidc-drift-apiserver-upgrade-stall.md`.
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**Primary fix (2026-06-24):** `stacks/rbac/modules/rbac/apiserver-oidc.tf` now
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@ -243,9 +244,9 @@ upgrades with a pure image bump — `kubeadm upgrade diff <target>` shows only t
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image change. Zero live impact (the CM is read only during an upgrade).
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**Backstops:**
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- **Preflight gate 4b** runs `kubeadm upgrade diff` and BLOCKs (k8s_upgrade_blocked=1
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→ alert) BEFORE draining the master if `--authentication-config` would still be
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dropped — so this can never again drain into a crash.
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- **Preflight check 4b** runs `kubeadm upgrade diff` and **alerts** (Slack WARN, does
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NOT block — the drift only breaks SSO, which is recoverable) if
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`--authentication-config` would still be dropped.
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- The `rbac` stack still publishes its restore script to the
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`kube-system/apiserver-oidc-restore` ConfigMap, and `phase_master` re-runs it on
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master right after `kubeadm upgrade apply` (idempotent, `/livez`-gated with
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