sounds like the largefiles issue, you should have seen this warning during the build:
Your Perl is uselargefiles enabled, but Apache is not, suggestions: *) Rebuild mod_perl with Makefile.PL PERL_USELARGEFILES=0 *) Rebuild Apache with CFLAGS="-D_LARGEFILE_SOURCE -D_FILE_OFFSET_BITS=64" *) Rebuild Perl with Configure -Uuselargefiles *) Let mod_perl build Apache (USE_DSO=1 instead of USE_APXS=1) easiest fix is the 1st option.