Finally I booted DIR-400 and came over the JFFS2 mount problem by "DISABLE GPIO". It was really strange but it works. I have no time to find what the reason is but I'll share the kernel config of openwrt first. Madwifi with new hal also works under AP mode without WEP.
1. kernel config of kernel 2.6.26.3 of DIR-400 with openwrt trunk r12507 (new madwifi hal)
CONFIG_32BIT=y
# CONFIG_64BIT is not set
CONFIG_AR2313=y
# CONFIG_ARCH_HAS_ILOG2_U32 is not set
# CONFIG_ARCH_HAS_ILOG2_U64 is not set
CONFIG_ARCH_POPULATES_NODE_MAP=y
# CONFIG_ARCH_SUPPORTS_MSI is not set
CONFIG_ARCH_SUPPORTS_OPROFILE=y
CONFIG_ARCH_SUSPEND_POSSIBLE=y
CONFIG_ATHEROS=y
CONFIG_ATHEROS_AR5312=y
CONFIG_ATHEROS_AR5315=y
# CONFIG_ATHEROS_AR5315_PCI is not set
# CONFIG_ATM is not set
# CONFIG_ATMEL is not set
CONFIG_BASE_SMALL=0
# CONFIG_BCM47XX is not set
CONFIG_BITREVERSE=y
# CONFIG_BROADCOM_PHY is not set
# CONFIG_BT is not set
CONFIG_CEVT_R4K=y
CONFIG_CLASSIC_RCU=y
CONFIG_CMDLINE="console=ttyS0,9600 rootfstype=squashfs,jffs2 root=/dev/mtdblock3 init=/etc/preinit mem=16M"
CONFIG_CPU_BIG_ENDIAN=y
CONFIG_CPU_HAS_LLSC=y
CONFIG_CPU_HAS_PREFETCH=y
CONFIG_CPU_HAS_SYNC=y
# CONFIG_CPU_LITTLE_ENDIAN is not set
# CONFIG_CPU_LOONGSON2 is not set
CONFIG_CPU_MIPS32=y
CONFIG_CPU_MIPS32_R1=y
# CONFIG_CPU_MIPS32_R2 is not set
# CONFIG_CPU_MIPS64_R1 is not set
# CONFIG_CPU_MIPS64_R2 is not set
CONFIG_CPU_MIPSR1=y
# CONFIG_CPU_NEVADA is not set
# CONFIG_CPU_R10000 is not set
# CONFIG_CPU_R3000 is not set
# CONFIG_CPU_R4300 is not set
# CONFIG_CPU_R4X00 is not set
# CONFIG_CPU_R5000 is not set
# CONFIG_CPU_R5432 is not set
# CONFIG_CPU_R6000 is not set
# CONFIG_CPU_R8000 is not set
# CONFIG_CPU_RM7000 is not set
# CONFIG_CPU_RM9000 is not set
# CONFIG_CPU_SB1 is not set
CONFIG_CPU_SUPPORTS_32BIT_KERNEL=y
CONFIG_CPU_SUPPORTS_HIGHMEM=y
# CONFIG_CPU_TX39XX is not set
# CONFIG_CPU_TX49XX is not set
# CONFIG_CPU_VR41XX is not set
CONFIG_CSRC_R4K=y
CONFIG_DEVPORT=y
# CONFIG_DM9000 is not set
CONFIG_DMA_NEED_PCI_MAP_STATE=y
CONFIG_DMA_NONCOHERENT=y
# CONFIG_E1000E_ENABLED is not set
# CONFIG_FIXED_PHY is not set
CONFIG_FS_POSIX_ACL=y
CONFIG_GENERIC_CLOCKEVENTS=y
CONFIG_GENERIC_CLOCKEVENTS_BUILD=y
CONFIG_GENERIC_CMOS_UPDATE=y
# CONFIG_GENERIC_FIND_FIRST_BIT is not set
CONFIG_GENERIC_FIND_NEXT_BIT=y
# CONFIG_GENERIC_GPIO=y
# CONFIG_GENERIC_HARDIRQS_NO__DO_IRQ is not set
# CONFIG_GPIO_DEVICE=y
CONFIG_HAS_DMA=y
CONFIG_HAS_IOMEM=y
CONFIG_HAS_IOPORT=y
# CONFIG_HAVE_DMA_ATTRS is not set
CONFIG_HAVE_IDE=y
# CONFIG_HAVE_KPROBES is not set
# CONFIG_HAVE_KRETPROBES is not set
CONFIG_HAVE_OPROFILE=y
# CONFIG_HERMES is not set
# CONFIG_HOSTAP is not set
# CONFIG_HW_HAS_PCI is not set
CONFIG_HW_RANDOM=y
# CONFIG_I2C is not set
# CONFIG_IBM_NEW_EMAC_EMAC4 is not set
# CONFIG_IBM_NEW_EMAC_RGMII is not set
# CONFIG_IBM_NEW_EMAC_TAH is not set
# CONFIG_IBM_NEW_EMAC_ZMII is not set
CONFIG_ICPLUS_PHY=y
# CONFIG_IDE is not set
CONFIG_INITRAMFS_SOURCE=""
CONFIG_IPV6_NDISC_NODETYPE=y
# CONFIG_IPW2100 is not set
# CONFIG_IPW2200 is not set
CONFIG_IRQ_CPU=y
# CONFIG_IWLWIFI_LEDS is not set
# CONFIG_LEDS_ALIX is not set
# CONFIG_LEDS_GPIO=y
# CONFIG_LEMOTE_FULONG is not set
CONFIG_LZO_COMPRESS=m
CONFIG_LZO_DECOMPRESS=m
# CONFIG_MACH_ALCHEMY is not set
# CONFIG_MACH_DECSTATION is not set
# CONFIG_MACH_JAZZ is not set
# CONFIG_MACH_VR41XX is not set
# CONFIG_MDIO_BITBANG is not set
# CONFIG_MEDIA_ATTACH is not set
CONFIG_MIPS=y
# CONFIG_MIPS_ATLAS is not set
# CONFIG_MIPS_COBALT is not set
CONFIG_MIPS_L1_CACHE_SHIFT=5
# CONFIG_MIPS_MALTA is not set
CONFIG_MIPS_MT_DISABLED=y
# CONFIG_MIPS_MT_SMP is not set
# CONFIG_MIPS_MT_SMTC is not set
# CONFIG_MIPS_SEAD is not set
# CONFIG_MIPS_SIM is not set
CONFIG_MTD=y
# CONFIG_MTD_ABSENT is not set
CONFIG_MTD_BLKDEVS=y
CONFIG_MTD_BLOCK=y
# CONFIG_MTD_BLOCK2MTD is not set
CONFIG_MTD_CFI=y
CONFIG_MTD_CFI_ADV_OPTIONS=y
CONFIG_MTD_CFI_AMDSTD=y
# CONFIG_MTD_CFI_BE_BYTE_SWAP is not set
# CONFIG_MTD_CFI_GEOMETRY is not set
CONFIG_MTD_CFI_I1=y
CONFIG_MTD_CFI_I2=y
# CONFIG_MTD_CFI_I4 is not set
# CONFIG_MTD_CFI_I8 is not set
# CONFIG_MTD_CFI_INTELEXT is not set
# CONFIG_MTD_CFI_LE_BYTE_SWAP is not set
CONFIG_MTD_CFI_NOSWAP=y
# CONFIG_MTD_CFI_STAA is not set
CONFIG_MTD_CFI_UTIL=y
CONFIG_MTD_CHAR=y
# CONFIG_MTD_CMDLINE_PARTS is not set
CONFIG_MTD_COMPLEX_MAPPINGS=y
# CONFIG_MTD_CONCAT is not set
# CONFIG_MTD_DEBUG is not set
# CONFIG_MTD_DOC2000 is not set
# CONFIG_MTD_DOC2001 is not set
# CONFIG_MTD_DOC2001PLUS is not set
CONFIG_MTD_GEN_PROBE=y
# CONFIG_MTD_JEDECPROBE is not set
CONFIG_MTD_MAP_BANK_WIDTH_1=y
# CONFIG_MTD_MAP_BANK_WIDTH_16 is not set
CONFIG_MTD_MAP_BANK_WIDTH_2=y
# CONFIG_MTD_MAP_BANK_WIDTH_32 is not set
CONFIG_MTD_MAP_BANK_WIDTH_4=y
# CONFIG_MTD_MAP_BANK_WIDTH_8 is not set
# CONFIG_MTD_MTDRAM is not set
# CONFIG_MTD_ONENAND is not set
# CONFIG_MTD_OTP is not set
CONFIG_MTD_PARTITIONS=y
# CONFIG_MTD_PCI is not set
# CONFIG_MTD_PHRAM is not set
CONFIG_MTD_PHYSMAP=y
CONFIG_MTD_PHYSMAP_BANKWIDTH=0
CONFIG_MTD_PHYSMAP_LEN=0x0
CONFIG_MTD_PHYSMAP_START=0x0
# CONFIG_MTD_PLATRAM is not set
# CONFIG_MTD_PMC551 is not set
# CONFIG_MTD_RAM is not set
CONFIG_MTD_REDBOOT_DIRECTORY_BLOCK=-3
CONFIG_MTD_REDBOOT_PARTS=y
CONFIG_MTD_REDBOOT_PARTS_READONLY=y
# CONFIG_MTD_ROM is not set
# CONFIG_MTD_SLRAM is not set
CONFIG_MTD_SPIFLASH=y
CONFIG_MVSWITCH_PHY=y
# CONFIG_NET_PCI is not set
# CONFIG_NET_VENDOR_3COM is not set
# CONFIG_NO_IOPORT is not set
# CONFIG_OCF_OCF is not set
CONFIG_PAGEFLAGS_EXTENDED=y
# CONFIG_PAGE_SIZE_16KB is not set
CONFIG_PAGE_SIZE_4KB=y
# CONFIG_PAGE_SIZE_64KB is not set
# CONFIG_PAGE_SIZE_8KB is not set
# CONFIG_PCI is not set
# CONFIG_PCIPCWATCHDOG is not set
# CONFIG_PCI_DOMAINS is not set
# CONFIG_PCSPKR_PLATFORM is not set
CONFIG_PHYLIB=y
# CONFIG_PMC_MSP is not set
# CONFIG_PMC_YOSEMITE is not set
# CONFIG_PNX8550_JBS is not set
# CONFIG_PNX8550_STB810 is not set
# CONFIG_PRISM54 is not set
# CONFIG_QSEMI_PHY is not set
# CONFIG_REALTEK_PHY is not set
CONFIG_RFKILL_LEDS=y
CONFIG_RTC_LIB=y
CONFIG_RWSEM_GENERIC_SPINLOCK=y
CONFIG_SCHED_NO_NO_OMIT_FRAME_POINTER=y
CONFIG_SCSI_WAIT_SCAN=m
# CONFIG_SERIAL_8250_EXTENDED is not set
CONFIG_SERIAL_8250_NR_UARTS=1
CONFIG_SERIAL_8250_RUNTIME_UARTS=1
# CONFIG_SGI_IP22 is not set
# CONFIG_SGI_IP27 is not set
# CONFIG_SGI_IP28 is not set
# CONFIG_SGI_IP32 is not set
# CONFIG_SIBYTE_BIGSUR is not set
# CONFIG_SIBYTE_CARMEL is not set
# CONFIG_SIBYTE_CRHINE is not set
# CONFIG_SIBYTE_CRHONE is not set
# CONFIG_SIBYTE_LITTLESUR is not set
# CONFIG_SIBYTE_RHONE is not set
# CONFIG_SIBYTE_SENTOSA is not set
# CONFIG_SIBYTE_SWARM is not set
CONFIG_SLABINFO=y
# CONFIG_SMSC_PHY is not set
# CONFIG_SOFT_WATCHDOG is not set
# CONFIG_SPARSEMEM_STATIC is not set
# CONFIG_SPARSEMEM_VMEMMAP_ENABLE is not set
CONFIG_SSB_POSSIBLE=y
CONFIG_SYSVIPC_SYSCTL=y
CONFIG_SYS_HAS_CPU_MIPS32_R1=y
CONFIG_SYS_SUPPORTS_32BIT_KERNEL=y
CONFIG_SYS_SUPPORTS_ARBIT_HZ=y
CONFIG_SYS_SUPPORTS_BIG_ENDIAN=y
# CONFIG_THERMAL is not set
# CONFIG_THERMAL_HWMON is not set
CONFIG_TICK_ONESHOT=y
# CONFIG_TOSHIBA_JMR3927 is not set
# CONFIG_TOSHIBA_RBTX4927 is not set
# CONFIG_TOSHIBA_RBTX4938 is not set
CONFIG_TRAD_SIGNALS=y
CONFIG_USB=m
# CONFIG_USB_EHCI_HCD is not set
# CONFIG_USB_ISIGHTFW is not set
CONFIG_USB_STORAGE_CYPRESS_ATACB=y
# CONFIG_USB_UHCI_HCD is not set
CONFIG_USB_WDM=m
# CONFIG_VGASTATE is not set
CONFIG_VIDEO_ALLOW_V4L1=y
CONFIG_VIDEO_MEDIA=m
CONFIG_VIDEO_V4L1=m
CONFIG_VIDEO_V4L2=m
CONFIG_VIDEO_V4L2_COMMON=m
CONFIG_ZONE_DMA_FLAG=0
CONFIG_ATHEROS_WDT=y
2. dmesg of DIR-400 with openwrt trunk r12507
RedBoot> load -r -b %{FREEMEMLO} fon/openwrt-fon-r12448/openwrt-atheros-vmlinux.lzma
Using default protocol (TFTP)
Raw file loaded 0x8003fc00-0x800efbff, assumed entry at 0x8003fc00
RedBoot> fis create -l 0xb0000 -f 0xbfc40000 -e 0x80041000 -r 0x80041000 vmlinux.bin.l7
An image named 'vmlinux.bin.l7' exists - continue (y/n)? y
... Erase from 0xbfc40000-0xbfcf0000: ...........
... Program from 0x8003fc00-0x800efc00 at 0xbfc40000: ...........
prog_ok
flash_addr = 0xbfc40000
mem_addr = 0x80041000
entry_addr = 0x80041000
length = 0xb0000
img_size = 0xb0000
... Erase from 0xbffe0000-0xbfff0000: .
... Program from 0x80ff0000-0x81000000 at 0xbffe0000: .
RedBoot> reset
+flash_hwr_init: flash device - id=21
Ethernet eth0: MAC address 00:1e:58:2d:a7:47
IP: 192.168.0.1/255.255.255.0, Gateway: 0.0.0.0
Default server: 192.168.0.100
RedBoot(tm) bootstrap and debug environment [ROMRAM]
Non-certified release, version UNKNOWN - built 16:18:06, Aug 21 2007
Copyright (C) 2000, 2001, 2002, 2003, 2004 Red Hat, Inc.
Board: ap61
RAM: 0x80000000-0x82000000, [0x8003fb80-0x80fe1000] available
FLASH: 0xbfc00000 - 0xbfff0000, 64 blocks of 0x00010000 bytes each.
board MAC = 13-44-21-33-20-08
== Executing boot script in 2.000 seconds - enter ^C to abort
RedBoot> fis load -l vmlinux.bin.l7
Image loaded from 0x80041000-0x80272086
RedBoot> exec
Now booting linux kernel:
Base address 0x80030000 Entry 0x80041000
Cmdline :
Linux version 2.6.26.3 (macpaul@debian) (gcc version 4.1.2) #1 Thu Sep 4 16:37:45 CST 2008
CPU revision is: 00019064 (MIPS 4KEc)
Determined physical RAM map:
memory: 02000000 @ 00000000 (usable)
User-defined physical RAM map:
memory: 01000000 @ 00000000 (usable)
Initrd not found or empty - disabling initrd
Zone PFN ranges:
Normal 0 -> 4096
Movable zone start PFN for each node
early_node_map[1] active PFN ranges
0: 0 -> 4096
Built 1 zonelists in Zone order, mobility grouping off. Total pages: 4064
Kernel command line: console=ttyS0,9600 rootfstype=squashfs,jffs2 root=/dev/mtdblock3 init=/etc/preinit mem=16M
Primary instruction cache 16kB, VIPT, 4-way, linesize 16 bytes.
Primary data cache 16kB, 4-way, VIPT, no aliases, linesize 16 bytes
PID hash table entries: 64 (order: 6, 256 bytes)
console [ttyS0] enabled
Dentry cache hash table entries: 2048 (order: 1, 8192 bytes)
Inode-cache hash table entries: 1024 (order: 0, 4096 bytes)
Memory: 13628k/16384k available (1822k kernel code, 2756k reserved, 300k data, 124k init, 0k highmem)
SLUB: Genslabs=6, HWalign=32, Order=0-3, MinObjects=0, CPUs=1, Nodes=1
Mount-cache hash table entries: 512
net_namespace: 484 bytes
NET: Registered protocol family 16
Radio config found at offset 0xf8(0x1f8)
NET: Registered protocol family 2
IP route cache hash table entries: 1024 (order: 0, 4096 bytes)
TCP established hash table entries: 512 (order: 0, 4096 bytes)
TCP bind hash table entries: 512 (order: -1, 2048 bytes)
TCP: Hash tables configured (established 512 bind 512)
TCP reno registered
NET: Registered protocol family 1
ar531x: Registering GPIODEV device
squashfs: version 3.0 (2006/03/15) Phillip Lougher
Registering mini_fo version $Id$
JFFS2 version 2.2. (NAND) (SUMMARY) �© 2001-2006 Red Hat, Inc.
msgmni has been set to 26
io scheduler noop registered
io scheduler deadline registered (default)
Serial: 8250/16550 driver $Revision: 1.90 $ 1 ports, IRQ sharing disabled
serial8250: ttyS0 at MMIO 0xb1100003 (irq = 37) is a 16550A
eth0: Atheros AR231x: 00:1e:58:2d:a7:48, irq 4
ar2313_eth_mii: probed
eth0: Marvell 88E6060 PHY driver attached.
eth0: attached PHY driver [Marvell 88E6060] (mii_bus:phy_addr=0:1f)
cmdlinepart partition parsing not available
Searching for RedBoot partition table in spiflash at offset 0x3d0000
Searching for RedBoot partition table in spiflash at offset 0x3e0000
6 RedBoot partitions found on MTD device spiflash
eth0: Configuring MAC for full duplex
Creating 6 MTD partitions on "spiflash":
0x00000000-0x00030000 : "RedBoot"
0x00030000-0x00040000 : "Config"
0x00040000-0x000f0000 : "vmlinux.bin.l7"
0x000f0000-0x003e0000 : "rootfs"
mtd: partition "rootfs" set to be root filesystem
mtd: partition "rootfs_data" created automatically, ofs=1F0000, len=1F0000
0x001f0000-0x003e0000 : "rootfs_data"
0x003e0000-0x003ef000 : "FIS directory"
0x003f0000-0x00400000 : "Calibration"
nf_conntrack version 0.5.0 (1024 buckets, 4096 max)
ip_tables: (C) 2000-2006 Netfilter Core Team
TCP vegas registered
NET: Registered protocol family 17
802.1Q VLAN Support v1.8 Ben Greear <greearb@candelatech.com>
All bugs added by David S. Miller <davem@redhat.com>
VFS: Mounted root (squashfs filesystem) readonly.
Freeing unused kernel memory: 124k freed
Please be patient, while OpenWrt loads ...
Algorithmics/MIPS FPU Emulator v1.5
- preinit -
Press CTRL-C for failsafe
switching to jffs2
mini_fo: using base directory: /
mini_fo: using storage directory: /jffs
- init -
Please press Enter to activate this console.
BusyBox v1.11.1 (2008-09-03 11:34:57 CST) built-in shell (ash)
Enter 'help' for a list of built-in commands.
_______ ________ __
| |.-----.-----.-----.| | | |.----.| |_
| - || _ | -__| || | | || _|| _|
|_______|| __|_____|__|__||________||__| |____|
|__| W I R E L E S S F R E E D O M
KAMIKAZE (bleeding edge, r12507) -------------------
* 10 oz Vodka Shake well with ice and strain
* 10 oz Triple sec mixture into 10 shot glasses.
* 10 oz lime juice Salute!
---------------------------------------------------
root@OpenWrt:/# PPP generic driver version 2.4.2
device eth0.0 entered promiscuous mode
device eth0 entered promiscuous mode
br-lan: port 1(eth0.0) entering learning state
br-lan: topology change detected, propagating
br-lan: port 1(eth0.0) entering forwarding state
wlan: trunk
ath_hal: module license 'Proprietary' taints kernel.
ath_hal: 2008-08-15 (AR5212, AR5312, RF5111, RF5112, RF2316, RF2317, REGOPS_FUNC, TX_DESC_SWAP, DFS, XR)
ath_rate_minstrel: Minstrel automatic rate control algorithm 1.2 (trunk)
ath_rate_minstrel: look around rate set to 10%
ath_rate_minstrel: EWMA rolloff level set to 75%
ath_rate_minstrel: max segment size in the mrr set to 6000 us
wlan: mac acl policy registered
ath_ahb: trunk
Atheros HAL provided by OpenWrt, DD-WRT and MakSat Technologies
wifi0: 11b rates: 1Mbps 2Mbps 5.5Mbps 11Mbps
wifi0: 11g rates: 1Mbps 2Mbps 5.5Mbps 11Mbps 6Mbps 9Mbps 12Mbps 18Mbps 24Mbps 36Mbps 48Mbps 54Mbps
wifi0: H/W encryption support: WEP AES AES_CCM TKIP
ath_ahb: wifi0: Atheros 2317 WiSoC REV2: mem=0xb0000000, irq=3
