I'm upgrading our VMs to the new tools package after upgrading to vSphere 4.1 and one of my CentOS 5 machines is giving an error of:
Creating a new initrd boot image for the kernel.
No module ehci-hcd found for kernel 2.6.18-194.8.1.el5, aborting.
ERROR: "/sbin/mkinitrd -f --with=vmxnet --with=vmxnet3 --with=pvscsi
/boot/initrd-2.6.18-194.8.1.el5.img 2.6.18-194.8.1.el5" exited with non-zero
Your system currently may not have a functioning init image and may not boot
properly. DO NOT REBOOT! Please ensure that you have enough free space
available in your /boot directory and run this configuration script again.
I can upgrade VMtools in other CentOS VM's
I checked the /boot partiction and have got enough free space.
What update level is the CentOS 5 VM at? Such as 5.4 or 5.5? Do you have the Yum Extender installed? If so, see what it gives you for available updates... I avoid using the included software update tool under RHEL or CentOS since Yum does a more complete job of things. Also check to see if the kernel-devel tools are fully up to date on the VM. I'm going to assume that you do have the gcc headers installed, make sure they are also up to date.
I had zero issue installing the VMTools on my CentOS 5.x VM's, but I also check them for updates at least once a month to make sure I'm not too far behind things.
How much free space do you have on the VM's disk(s)? Is it thick or thin provisioned? If thin, check to make sure the datastore has enough room to grow.
BTW, the kernel version of my CentOS VM's is 2.6.18-194.11.1.el5 and above...
Consider awarding points for "helpful" and/or "correct" answers.
You might want to have a look at the Operating System Specific Packages (OSP). Once set up you can install / upgrade VMware tools with YUM. http://www.vmware.com/download/packages.html