Description:

After the udev-178-1 and/or filesystem-2011.12-2 package(s) update I have the following issue:

The partition under /usr cannot be checked at the boot time anymore (because is already mounted) and the boot process displays the manual maintenance message but here you cannot fsck becuase few processess (ex: bash, udevd and bootlog) are using libraries from /usr/lib. Booting with init=/bin/sh and manually perform a fsck on this partition works but at the next boot the same issue occurs again.

Please find below the booting process log after I've changed the /etc/rc.sysinit to declare fsckret=0 always:

Tue Jan 24 13:25:51 2012: :: Starting UDev Daemon [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Triggering UDev uevents [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Waiting for UDev uevents to be processed [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Bringing up loopback interface [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Activating LVM2 groups [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Unlocking encrypted volumes: [BUSY] ^[[uhome..
Tue Jan 24 13:25:51 2012: Opening 'home' volume:
Tue Jan 24 13:25:51 2012: ^[[uok [DONE]
Tue Jan 24 13:25:51 2012: :: Activating LVM2 groups [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Checking Filesystems [BUSY] /dev/sda6: clean, 42550/652800 files, 1678053/2606538 blocks
Tue Jan 24 13:25:51 2012: /dev/sda5: clean, 43/50200 files, 75514/200780 blocks
Tue Jan 24 13:25:51 2012: /dev/mapper/work-usr is mounted. e2fsck: Cannot continue, aborting.
Tue Jan 24 13:25:51 2012:
Tue Jan 24 13:25:51 2012:
Tue Jan 24 13:25:51 2012: /dev/mapper/work-var: clean, 55927/655360 files, 960288/2621440 blocks
Tue Jan 24 13:25:51 2012: /home: clean, 82956/1998848 files, 6890338/7995136 blocks
Tue Jan 24 13:25:51 2012: [DONE]
Tue Jan 24 13:25:51 2012: :: Remounting Root [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Mounting Local Filesystems [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Activating Swap [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Configuring Time Zone [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Initializing Random Seed [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Removing Leftover Files [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Setting Hostname: archlinux [BUSY] [DONE]
Tue Jan 24 13:25:51 2012: :: Setting Consoles to UTF-8 mode [BUSY] [DONE]
Tue Jan 24 13:25:52 2012: :: Loading Keyboard Map: us [BUSY] [DONE]
Tue Jan 24 13:25:52 2012: :: Saving dmesg Log [BUSY] [DONE]
Tue Jan 24 13:25:52 2012: INIT: Entering runlevel: 3
Tue Jan 24 13:25:52 2012: :: Starting RSyslogd [BUSY] [DONE]
Tue Jan 24 13:25:52 2012: :: Starting D-BUS system messagebus [BUSY] [DONE]
Tue Jan 24 13:25:53 2012: > No profile started.
Tue Jan 24 13:25:53 2012: :: Starting NetworkManager [BUSY] [DONE]
Tue Jan 24 13:25:54 2012: :: Starting alsa [BKGD]
Tue Jan 24 13:25:54 2012: :: Starting crond [BKGD]
Tue Jan 24 13:25:54 2012: :: Starting cupsd daemon [BUSY] Found hardware: "HDA-Intel" "Intel Cantiga HDMI" "HDA:111d76b2,1028024d,00100302 HDA:80862802,80860101,001000
Tue Jan 24 13:25:54 2012: Hardware is initialized using a generic method
Tue Jan 24 13:25:56 2012: [DONE]
Tue Jan 24 13:25:56 2012: :: Starting gpm [BKGD]
Tue Jan 24 13:25:56 2012: :: Setting cpufreq governing rules [BUSY] ^[[u, cpu^[[u 0^[[u 1^[[
Tue Jan 24 13:25:56 2012: :: Starting nscd [BKGD]
Tue Jan 24 13:25:56 2012: :: Starting OpenNTPD [BUSY] [DONE]
Tue Jan 24 13:25:56 2012: :: Starting GDM [BUSY] [DONE]

Additional info:
- I am using a custom kernel that has the devtmpfs option but the issue occurs also with the archlinux' official 3.2.1 kernel
- the /usr is mounted on a lvm volume
- the /home is mounted on a luks encrypted partition (lvm volume)

- # cat /etc/cryptab LUKS
home /dev/work/lvmhome ASK

- #cat /etc/fstab
devpts /dev/pts devpts defaults 0 0
shm /dev/shm tmpfs nodev,nosuid 0 0
/dev/sda5 /boot ext2 defaults 0 1
/dev/sda6 / ext3 defaults,noatime 0 1
/dev/mapper/work-usr /usr ext3 rw,noatime 0 2
/dev/mapper/work-var /var ext3 rw,noatime 0 2
/dev/mapper/home /home ext4 rw,noatime,data=writeback,nobarrier,nouser_xattr,commit=600 0 2

- #cat /etc/rc.conf | grep -v -E "^#|^$"
HARDWARECLOCK="UTC"
TIMEZONE="Europe/Amsterdam"
KEYMAP="us"
CONSOLEFONT=
CONSOLEMAP=
LOCALE="en_US.UTF-8"
DAEMON_LOCALE="yes"
USECOLOR="yes"
MODULES=()
USEDMRAID="no"
USEBTRFS="no"
USELVM="yes"
HOSTNAME="archlinux"
interface=eth0
address=
netmask=
broadcast=
gateway=
NETWORK_PERSIST="no"
DAEMONS=(!hwclock rsyslogd dbus !network net-profiles networkmanager !iptables !netfs @alsa @crond cupsd @gpm cpufreq @nscd openntpd !squid !libvirtd gdm)

Steps to reproduce:
- using a similar partitioning scheme