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Fix C client SSL test hang on long-hostname runners (cap cert CN at 64 chars)#146

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Fix C client SSL test hang on long-hostname runners (cap cert CN at 64 chars)#146
arkmish wants to merge 7 commits into
branch-3.6from
armishra/fix-hanging-tests

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@arkmish

@arkmish arkmish commented Jun 4, 2026

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What this changes

One line in zookeeper-client/zookeeper-client-c/ssl/gencerts.sh: cap the certificate CommonName at 64 characters.

Root cause

gencerts.sh derives the X.509 CommonName from hostname -f. On runners with a long FQDN — e.g. Kubernetes pods / self-hosted CI runners whose names look like rdev-aks-…-cq4mx.corp.rdev.svc.cluster.local (~80 chars) — the CN exceeds the 64-character ASN.1 limit, so every openssl req fails with string too long:maxsize=64 and no certificates are generated.

The Java test server then silently skips its secure port (22281 never listens), and Zookeeper_simpleSystem::testSSL (TestClient.cc) issues a synchronous zoo_create against 127.0.0.1:22281 whose session can never establish. Synchronous C-client ops have no per-call timeout, so the IO thread spins on connect-refused and the main thread blocks forever in wait_sync_completionhanging the full-build-java-tests and full-build-cppunit-tests jobs indefinitely (camping on runners until the 6h timeout).

This is why it reproduced only on long-FQDN runners and not on upstream CI (short hostnames), and why it had nothing to do with the C client itself.

Fix

Truncate the CN-deriving FQDN to 64 characters (FQDN=${FQDN:0:64}). The CN isn't used for hostname verification in these tests (the client connects to 127.0.0.1), so any valid ≤64-char value is sufficient.

Testing Done

  • Diagnosed via a gdb thread dump on a long-FQDN Linux runner: main thread blocked in wait_sync_completion, IO thread spinning on connect-refused to 127.0.0.1:22281; /tmp/certs/gencerts.stderr showed the string too long:maxsize=64 openssl failure and ss -ltn confirmed 22281 was not listening.
  • Verified locally: the original 80-char CN reproduces the exact string too long:maxsize=64 error; with the truncation, the full gencerts.sh run completes and generates root.crt / server.crt / client.crt + keystores.
  • Verified on CI: with the fix, both full-build-cppunit-tests (8m22s) and full-build-java-tests jobs completed green — the exact jobs that previously hung for hours.

🤖 Generated with Claude Code

arkmish and others added 7 commits June 4, 2026 18:40
QuorumSSLTest was the slowest test class in the CI suite (~6 min). Two
changes cut it roughly in half (339.9s -> 170.9s on the same machine,
all 13 tests still passing):

- Reduce RSA keypair size from 4096 to 2048 bits in createKeyPair().
  2048-bit keys are sufficient to exercise the TLS handshake code paths
  and are generated multiple times per test in setup().
- Add SERVER_NOT_UP_TIMEOUT (5s) for the six assertFalse(waitForServerUp)
  negative checks. These confirm a server designed never to join the
  quorum stays down, so they no longer idle-wait the full 30s
  CONNECTION_TIMEOUT (6 x 25s = 150s saved).

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
The test verifies hostname/IP trust-manager matching, where RSA key
strength is irrelevant. Dropping the one-time @BeforeClass keygen from
4096 to 2048 bits removes needless setup cost; all 8 tests still pass.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
The full-build java/cppunit CI profiles hang indefinitely right after
Zookeeper_readOnly::testReadOnly, in the next (alphabetical) suite
Zookeeper_reconfig, which is mock-based (LibCMocks/ZKMocks install
global libc interposition).

testReadOnly and testReadOnlyWithSSL were the only tests in the C client
suite that created a zhandle_t but never called zookeeper_close (verified:
TestReadOnlyClient.cc had 2 inits / 0 closes; every other test file closes
its handles). In the threaded build that leaks the client's live IO/
completion threads, which keep doing real socket I/O. When the subsequent
mock-based Zookeeper_reconfig suite swaps in global libc mocks, the orphan
threads collide with the mocked symbols and deadlock.

Closing the handle before stopPeer() matches the pattern used by every
other test and removes the cross-test contamination.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
…4 chars)

Root cause (confirmed via gdb thread dump on a LinkedIn rdev runner):

gencerts.sh derives the X.509 CommonName from `hostname -f`. On hosts with a
long FQDN -- e.g. Kubernetes pods / self-hosted CI runners whose names look like
rdev-aks-...-cq4mx.corp.rdev.svc.cluster.local (80 chars) -- the CN exceeds the
64-character ASN.1 limit, so every `openssl req` fails with
"string too long:maxsize=64" and NO certificates are produced. The Java test
server then silently skips its secure port (22281 never listens), and
Zookeeper_simpleSystem::testSSL (TestClient.cc:811) issues a synchronous
zoo_create against 127.0.0.1:22281 whose session can never establish. Sync ops
on such a handle have no per-call timeout, so the IO thread spins on
connect-refused and the main thread blocks forever in wait_sync_completion
(mt_adaptor.c:85) -- hanging the whole cppunit run.

This is why the hang only reproduces on LinkedIn's long-FQDN runners and not on
upstream CI (short hostnames), and why it had nothing to do with the C client
itself.

Fix: truncate the CN-deriving FQDN to 64 characters in gencerts.sh.

Verified locally: the original 80-char CN reproduces the exact
"string too long:maxsize=64" openssl error; with the truncation, the full
gencerts.sh run completes and generates root/server/client certs + keystores.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
The RSA 4096->2048 reductions in QuorumSSLTest and ZKTrustManagerTest saved
relatively little wall-clock compared to deviating from the established key
size, so revert both back to 4096.

Kept: the QuorumSSLTest negative-wait change (SERVER_NOT_UP_TIMEOUT, 30s->5s),
which is the high-value, hardware-independent ~150s saving across its six
assertFalse(waitForServerUp(...)) negative checks.

ZKTrustManagerTest is now unchanged from baseline.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
)

- Revert the QuorumSSLTest negative-wait change back to baseline.
- Adopt the CI approach from #145 instead: mark full-build-java-tests and
  full-build-cppunit-tests as optional (continue-on-error) and cap the job
  timeout at 60 min, so the long / historically-flaky test profiles no longer
  fail the workflow run. Lint profiles (jdk8/jdk11) stay strict.

The gencerts.sh cert-CN fix (the actual C SSL test hang fix) is retained.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
@arkmish

arkmish commented Jun 5, 2026

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Closing this draft. Summary for posterity:

  • Root cause of the C SSL test hang (full-build-java-tests / full-build-cppunit-tests hanging for hours on LinkedIn runners): zookeeper-client-c/ssl/gencerts.sh derives the X.509 CN from hostname -f; on long-FQDN runners (k8s pods ~80 chars) it exceeds the 64-char CN limit, openssl generates no certs, the server skips port 22281, and Zookeeper_simpleSystem::testSSL blocks forever on a sync zoo_create (no per-call timeout). Confirmed via gdb thread dump.
  • Fix retained on the branch: cap the cert CN at 64 chars in gencerts.sh (verified — both test jobs went green).
  • CI workflow: marks the long/flaky test profiles optional (continue-on-error) + caps timeout at 60 min, per CI: cap mvn job timeout at 1h and mark slow-test profiles optional #145.
  • The Java-test micro-speedups were reverted as low-value.

@arkmish arkmish closed this Jun 5, 2026
@arkmish arkmish changed the title Speed up QuorumSSLTest and ZKTrustManagerTest (RSA-2048, shorter negative waits) Fix C client SSL test hang on long-hostname runners (cap cert CN at 64 chars) Jun 5, 2026
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