@cmb:
There's nothing unstable about OpenVPN client, it's one of the most widely used things. You have some kind of problem that isn't a bug, but no telling from that description what that might be.
cmb, I had the WAN disconnected for 24 hours and now that I reconnected WAN the OpenVPN client didn't come up. I think I have nailed the problem to be with OpenVPN exiting when there is no WAN connection - This shouldn't happen and OpeVPN client should keep trying or it should be smart enough to come up the moment there is a WAN connection detected again. So, something is failing here. Following is the log:
[b]Mar 3 22:43:48 openvpn[39786]: SIGTERM[hard,] received, process exiting
Mar 3 22:43:48 openvpn[62930]: UDPv4 link local (bound): [AF_INET]192.168.254.10:47383
Mar 3 22:43:48 openvpn[62930]: UDPv4 link remote: [undef]
Mar 3 22:43:48 openvpn[63453]: OpenVPN 2.2.0 i386-portbld-freebsd8.1 [SSL] [LZO2] [eurephia] [MH] [PF_INET6] [IPv6 payload 20110424-2 (2.2RC2)] built on Aug 6 2012
Mar 3 22:43:48 openvpn[63453]: NOTE: the current --script-security setting may allow this configuration to call user-defined scripts
Mar 3 22:43:48 openvpn[63453]: LZO compression initialized
Mar 3 22:43:48 openvpn[63453]: TUN/TAP device /dev/tun1 opened
Mar 3 22:43:48 openvpn[63453]: do_ifconfig, tt->ipv6=0, tt->did_ifconfig_ipv6_setup=0
Mar 3 22:43:48 openvpn[63453]: /sbin/ifconfig ovpnc1 172.18.18.2 172.18.18.1 mtu 1500 netmask 255.255.255.255 up
Mar 3 22:43:48 openvpn[63453]: /usr/local/sbin/ovpn-linkup ovpnc1 1500 1561 172.18.18.2 172.18.18.1 init
Mar 3 22:43:48 openvpn[4443]: UDPv4 link local (bound): [AF_INET]192.168.254.10
Mar 3 22:43:48 openvpn[4443]: UDPv4 link remote: [AF_INET]65.64.64.64:54344
Mar 3 22:43:48 openvpn[4443]: Peer Connection Initiated with [AF_INET]65.64.64.64:54344
Mar 3 22:43:49 openvpn[4443]: Initialization Sequence Completed
Mar 4 09:32:24 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:25 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:26 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:27 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:28 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:29 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:30 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:31 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:32 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:33 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:34 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:35 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:36 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:37 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:38 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:39 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:40 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:41 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:42 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:43 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:44 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:45 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:46 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:47 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:48 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:49 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:50 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:51 openvpn[4443]: write UDPv4: No route to host (code=65)
Mar 4 09:32:52 openvpn[4443]: Inactivity timeout (--ping-restart), restarting
Mar 4 09:32:52 openvpn[4443]: SIGUSR1[soft,ping-restart] received, process restarting
Mar 4 09:32:54 openvpn[4443]: NOTE: the current --script-security setting may allow this configuration to call user-defined scripts
Mar 4 09:32:54 openvpn[4443]: Re-using pre-shared static key
Mar 4 09:32:54 openvpn[4443]: LZO compression initialized
Mar 4 09:32:54 openvpn[4443]: TCP/UDP: Socket bind failed on local address [AF_INET]192.168.254.10: Can't assign requested address
Mar 4 09:32:54 openvpn[4443]: Exiting
Mar 4 09:32:54 openvpn[4443]: /usr/local/sbin/ovpn-linkdown ovpnc1 1500 1561 172.18.18.2 172.18.18.1 init[/b]
List of process running at this moment as it might be relevant per this link = https://forums.openvpn.net/topic8933.html :
$ top
last pid: 25694; load averages: 0.00, 0.00, 0.00 up 0+22:43:15 19:40:08
34 processes: 1 running, 33 sleeping
Mem: 39M Active, 24M Inact, 41M Wired, 8K Cache, 34M Buf, 130M Free
Swap:
PID USERNAME THR PRI NICE SIZE RES STATE TIME WCPU COMMAND
24839 root 1 46 0 36564K 24408K piperd 0:49 1.95% php
262 root 1 76 20 3408K 1208K kqread 3:25 0.00% check_reload_status
466 root 1 76 20 3656K 1460K wait 1:06 0.00% sh
48841 root 1 64 20 6080K 6104K select 0:15 0.00% ntpd
24156 root 1 44 0 8764K 6628K kqread 0:08 0.00% lighttpd
32953 dhcpd 1 44 0 8436K 5688K select 0:07 0.00% dhcpd
62930 root 1 64 20 5116K 3304K select 0:05 0.00% openvpn
33857 nobody 1 44 0 5564K 2552K select 0:02 0.00% dnsmasq
16616 root 1 44 0 5912K 2368K bpf 0:02 0.00% tcpdump
24408 root 1 46 0 35540K 19848K accept 0:02 0.00% php
16411 root 1 44 0 4956K 2436K select 0:01 0.00% syslogd
48534 root 1 64 20 3316K 1352K select 0:01 0.00% apinger
16778 root 1 44 0 3316K 904K piperd 0:00 0.00% logger
49678 root 1 44 0 3408K 1388K nanslp 0:00 0.00% cron
54249 root 1 71 0 3316K 1040K nanslp 0:00 0.00% minicron
17024 root 1 44 0 3436K 1444K select 0:00 0.00% inetd
63848 root 1 76 0 3688K 1576K wait 0:00 0.00% login
282 root 1 44 0 1888K 532K select 0:00 0.00% devd
***The only other VPN process on this pfSense is a VPN server.
It seems like once WAN is connected some script is not notifying OpenVPN tunnel to restart so it just stays stopped.
***I think this issue is closely related to this issue: http://forum.pfsense.org/index.php/topic,2785.30.html
Thanks