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WILINK8-WIFI-MCP8: WiLink8 module doesn't work across all test systems

Ryan May85
Intellectual 330 points
Part Number: WILINK8-WIFI-MCP8 
We're in the process of updating the kernel for one of our boards (an
AM335X-based system, architecturally very similar to the AM335X EVM),
and have run into some problems with the WiLink8.  After updating the
kernel from 3.14 to 4.9 (with matching updates to userspace and the .dts
file for our board, not in the mainline kernel), on some individual
boards, the WiLink8 always works, and on some other individual boards,
it never shows up (no wlan0/wlp* in the output of "ip l", no "wlcore:
wl18xx HW: 183x or 180x, PG 2.2 (ROM 0x11)" message in the kernel log,
nothing).  All individual boards behave identically (i.e. the WiLink8
works) with the old kernel/userspace, even after running the new
kernel/userspace.

Obviously from 3.14 to 4.9 is quite the jump, and our first thought was
that we must have got something wrong when we updated our .dts file.  We
did find a couple of problems, but now we're left with no obvious
significant differences between our .dts file and the mainline kernel's
am335x-evm.dts file that we can't justify, and the problem continues
exactly has it has been.

I've read back through the WL18XX platform integration guide [0].  Apart
from the age of the document, and the specific pins being used,
everything looks right.  All the right kernel modules are loaded (same
on working/non-working systems).

[0] http://processors.wiki.ti.com/index.php/WL18xx_Platform_Integration_Guide

Any idea what might be wrong, or what we might need to check next?

The attached kern.log files were generated on a working system and a
non-working system, both running the same kernel, with CONFIG_MMC_DEBUG
enabled (which isn't helping much).  They aren't actually attached since there is a file size
limit.  Please see logs here: 
drive.google.com/.../1nsuCnwZpBQCNqsUziWeQbGLFG1bfF4sF

1018.am335x-icg.dts.txt
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/*
* Copyright (C) 2014 Intwine Connect - http://www.intwineconnect.com/
*
* This program is free software; you can redistribute it and/or modify
* it under the terms of the GNU General Public License version 2 as
* published by the Free Software Foundation.
*/
/dts-v1/;
#include "am33xx.dtsi"
#include <dt-bindings/interrupt-controller/irq.h>
/ {
model = "TI AM335x ICG P3";
compatible = "ti,am33xx", "ti,omap3";
cpus {
cpu@0 {
cpu0-supply = <&vdd1_reg>;
};
};
memory@80000000 {
device_type = "memory";
reg = <0x80000000 0x20000000>; /* 512 MB */
};
chosen {
stdout-path = &uart0;
};
vbat: fixedregulator0 {
compatible = "regulator-fixed";
regulator-name = "vbat";
regulator-min-microvolt = <5000000>;
regulator-max-microvolt = <5000000>;
regulator-boot-on;
};
wlan_en_reg: fixedregulator2 {
compatible = "regulator-fixed";
regulator-name = "wlan-en-regulator";
regulator-min-microvolt = <1800000>;
regulator-max-microvolt = <1800000>;
/* WLAN_EN GPIO for this board - Bank3, pin3 */
gpio = <&gpio3 3 GPIO_ACTIVE_HIGH>;
/* WLAN card specific delay */
startup-delay-us = <70000>;
enable-active-high;
};
vtt_fixed: fixedregulator3 {
compatible = "regulator-fixed";
regulator-name = "vtt";
regulator-min-voltage = <1500000>;
regulator-max-voltage = <1500000>;
gpio = <&gpio0 7 GPIO_ACTIVE_HIGH>;
regulator-always-on;
regulator-boot-on;
enable-active-high;
};
kim {
compatible = "kim";
nshutdown_gpio = <117>; /* Bank3, pin21 */
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