myasnikovdaniil 2b90e8cf45 [Backport release-1.6] fix(kubernetes): break bootstrap-token Job out of Helm hook to unblock fresh installs (#4541)
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## What this PR does

Backports #3887 to `release-1.6`. The fix reached `main` only: `v1.6.3`
and `v1.6.4` both still ship the bootstrap-token Job as a
`post-install,post-upgrade` Helm hook, and `git tag --contains` on the
merge commit returns `v1.7.0-alpha.1` and nothing from the 1.6 line.
Tracked as #4539.

#3875 describes the deadlock this removes: the chart upgrade waits for
`MachineDeployment` and the child HelmReleases, workers cannot register
without the `bootstrap-token-<id>` Secret in the guest cluster, and the
hook that creates that Secret only runs once the wait has already
succeeded. The wait cannot succeed without nodes, so the upgrade times
out and Flux retries the same cycle indefinitely.

It is deterministic rather than flaky, and it takes out every tenant
Kubernetes cluster on the platform at once. What makes the backport
worth filing separately: anyone hitting this on 1.6.3 finds #3875 closed
in the tracker, upgrades to 1.6.4 expecting the fix, and lands in
exactly the same state.

Observed on a production cluster before the manual workaround: machines
stuck in `Provisioned` with no `NODENAME`, VMIs `Running` with IPs
assigned, guest clusters reporting `No resources found` for nodes, and
no bootstrap-token Secret anywhere in the guest `kube-system`. Creating
the Secret by hand brought nodes up within 90 seconds on each affected
tenant.

`git cherry-pick --mainline 1` of the merge commit applied cleanly with
no conflicts, and nothing was changed on top: the diff here is identical
to what merged on `main`.

Validation, `helm unittest` in `packages/apps/kubernetes` including
`tests/talos_templates_test.yaml` which this change extends:

```
Charts:      1 passed, 1 total
Test Suites: 19 passed, 19 total
Tests:       189 passed, 189 total
```

### Screenshots

Not applicable, no UI changes.

### Downstream repositories

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- [x] No downstream repository is affected by this change
- [ ] [cozystack/website](https://github.com/cozystack/website) -
follow-up:
- [ ]
[cozystack/terraform-provider-cozystack](https://github.com/cozystack/terraform-provider-cozystack)
- follow-up:
- [ ]
[cozystack/ansible-cozystack](https://github.com/cozystack/ansible-cozystack)
- follow-up:
- [ ] [cozystack/ccp](https://github.com/cozystack/ccp) - follow-up:
- [ ] [cozystack/talm](https://github.com/cozystack/talm) - follow-up:
- [ ] [cozystack/cozyhr](https://github.com/cozystack/cozyhr) -
follow-up:
- [ ] [cozystack/cozy-proxy](https://github.com/cozystack/cozy-proxy) -
follow-up:
- [ ]
[cozystack/cozystack-telemetry-server](https://github.com/cozystack/cozystack-telemetry-server)
- follow-up:
- [ ]
[cozystack/external-apps-example](https://github.com/cozystack/external-apps-example)
- follow-up:
- [ ] [cozystack/examples](https://github.com/cozystack/examples) -
follow-up:

### Release note

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```release-note
fix(kubernetes): create the tenant bootstrap-token Secret outside the Helm hook, so Talos workers can register during a chart upgrade instead of deadlocking against the wait that needs them
```
2026-10-16 11:45:35 +05:00
2025-10-08 09:43:34 +05:00
2025-04-01 18:48:14 +02:00
2024-02-08 12:04:32 +01:00

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