We had roughly the same experience. Downgrading to passenger 2.2.2 fixed 
this issue for us.

The only way how 2.2.5 worked was by adding always_restart.txt, which 
severely affects performance.

scott wrote:
> I recently upgraded to Puppet 0.25 and am trying to migrate to
> Passenger but am noticing a strange problem.  It appears code is being
> cached inappropriately and puppet is refusing to hand out manifests or
> files since they aren't authorized.
>
> If I restart httpd and then run two puppet clients in succession, the
> following is logged on the master:
>
> Oct  6 19:27:35 [redactedmaster] puppetmasterd[18777]: Starting Puppet
> server version 0.25.0
> Oct  6 19:27:36 [redactedmaster] puppetmasterd[18777]: Compiled
> catalog for [redacted-hostA] in 0.62 seconds
> Oct  6 19:27:41 [redactedmaster] puppetmasterd[18777]: Denying access:
> Forbidden request: [redacted-hostA] (ip) access to /catalog/[redacted-
> hostB] [find] authenticated  at line 0
> Oct  6 19:27:41 [redactedmaster] puppetmasterd[18777]: Forbidden
> request: [redacted-hostA] (ip) access to /catalog/[redacted-hostB]
> [find] authenticated  at line 0
>
> Putting always_restart.txt into rack/tmp/ solves this, at the cost of
> some very verbose apache logging and presumably decreased
> performance.  I've tried setting the Passenger spawn method to
> Conservative which did not seem to help.
>
> I'm very much a Passenger newbie but would prefer not to run mongrel
> if I can avoid it.  Is this a known problem?  Did I overlook a setting
> somewhere?  The standalone server with webrick displays no such issue.
>
> -Scott
>
>
>
>
> >
>   


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