Cases2 cases

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1. IL-0101 After Google forced a GKE control plane upgrade to 1.33.2 at a deprecation deadline, no new node could initialise, so autoscaling and spot node replacement stopped for 15 hours

   Wealthy2025sev1

   Symptoms

   Nodes that already existed kept running, but every new node, spot or standard, on either v1.32 or v1.33, failed to initialise and could not join the cluster. Spot nodes that were preempted and recreated never came back, so services degraded progressively: background workers on spot instances, reporting services and order allocation stopped completely, and the APIs on existing nodes kept answering but could not scale for load spikes.

   Scale-up failureContainer crash loopService outageDNS resolution failures

   Trigger

   Google upgraded the GKE control plane from v1.32.x to v1.33.2 at the version deprecation deadline, although auto-upgrade was disabled on the node pools.

   Root cause

   Breaking change in an upgrade

   Component

   GKE control planeNode poolClient-side DNS resolver and cachePersistent volumes and stateful setsConfigMaps and Secrets

   Contributing factor

   Deferred upgradesSingle point of failureIneffective rollbackNo headroom

   Remediation

   • Created a new GKE cluster at v1.33, the version of the forced upgrade
   • Upgraded Istio to 1.27.1 for Kubernetes 1.33 compatibility
   • Updated the cert-manager configuration for Kubernetes 1.33
   • Migrated all production workloads to the new cluster and verified pod scheduling, DNS resolution, PVC mounting and external integrations
   • Decommissioned the broken cluster

   Action items

   • Configure all clusters to use the GKE stable release channel
   • Implement a separate management cluster for Argo CD, monitoring and other control components (Q4 2025)
   • Review spot instance usage for critical workloads and add on-demand fallback pools
   • Document the SRE upgrade procedure: management cluster first, production after a monitoring period of several days
   • Document a Kubernetes, Istio and cert-manager compatibility matrix
   • Create an automated upgrade testing pipeline
   • Reserve static IPs for quick migrations
   • Pin versions of Istio, cert-manager, CSI and DNS addons
   • Stay current with stable releases and regularly check GKE alerts and announcements to avoid deprecation deadlines

   Lessons

   GKE upgrades the control plane at a version's deprecation deadline even when auto-upgrade is disabled, so staying inside the supported version window is how to avoid a forced upgrade. A control plane upgrade can leave existing nodes healthy while every new node fails, and spot nodes that cannot rejoin after preemption turn this into cascading failures. Relying heavily on spot instances for critical workers turned a node join failure into a progressive outage. Kubernetes upgrades have to be planned together with dependent components such as Istio and cert-manager, and without a standby cluster on the same provider there was no immediate failover; the only recovery left was building a new cluster.

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2. IL-0449 Pods on Enigmo's new EKS managed node groups kept restarting or stuck Terminating and the nodes became unusable

   Enigmo2020

   Symptoms

   Two or three days after Enigmo created EKS managed node groups and moved its pods there from the old node groups, the cluster suddenly became unstable: pods restarted again and again or could not stop and stayed around indefinitely, node CPU and memory load rose high, and the nodes became unusable from the cluster.

   Pods stuck in TerminatingSustained high node CPUMemory pressureNode NotReadyUpgrade stall

   Trigger

   Enigmo created EKS managed node groups that used an AMI containing the bug and moved its pods onto them, as preparation for upgrading EKS from 1.15 to 1.16.

   Root cause

   Breaking change in an upgrade

   Component

   Node operating system imageNode pool

   Contributing factor

   Ineffective rollbackChange with a delayed effect

   Remediation

   • Changed the managed node groups' AMI version to the fixed release
   • Ran the managed node group update through CloudFormation
   • Watched the pods across all namespaces during the update
   • Force-deleted every pod that stayed in Terminating with kubectl delete --grace-period=0 --force

   Action items

   • Check the latest releases of the cluster's modules quarterly or monthly and upgrade them regularly

   Lessons

   As long as a team uses Amazon EKS or Kubernetes, it has to keep track of upgrades of the cluster and of modules such as ingress controllers, because a release with breaking changes can be announced without warning after a long stable period. Checking releases and upgrading on a regular schedule keeps the effect of each upgrade on the service small.

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