I could do some test based on the recommendations by KOM and johnpoz. For my situation, it seems i was to stingy with the hardware settings on my vm's.
Since i upgraded vCPU's from 1 to 2 and vRAM from 512mb to 1024mb, the problems are gone.
While setting up the appliances i configured with this guide: https://doc.pfsense.org/index.php/PfSense_2_on_VMware_ESXi_5.
There they speak about 1vCPU and 512mb vRAM if you have e few or no packages. I only use OPENVPN Client Export Packages in addition to the baseimage. So i thought 512mb will be enough.
Now the error/problem is reproducable. when i go back to 512mb vRAM and change some NAT/firewall rules (only enabling/disabling) pfSense stops working as described earlier after about 20-30klicks.
With 1024mb vRAM the error does not occour, even with 100dreds of klicks. ;)
My presumption ist that pfSense 2.2 with FreeBSD 10.x requires more vRAM the in older releases.
Here for Reference my complete seetings:
ESXi 5.5 Build 2456374 / pfSenseVM: HW-Version 8, FreeBSD 64bit, 2vCPU, 1024MB vRAM, 8GB vDisk Thick, 2xE1000 NIC
BTW: the ancient ESXi Version i was using before has nothing to do with the problem. the problem is reproduced on the my old ESXi box aswell on the new.