I (used to) maintain a server with an app that did this as well. The code on staging worked, but was at CF9 with no patches. The production server was at 901. Staging had no firewall, but production is in a DMZ. We never did determine a "why" for this happening, and it ONLY happened on calls made by the server to itself (cfhttp, cfdocument, etc). We boiled it down to something that changed with CF901 that's not documented. My only recommendation was to move off of client variables to a different shared session scope.
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