I have reopen issue http://jira.jboss.com/jira/browse/JBINSTALL-93. Also look
at JBINSTALL-244 and JBINSTALL-245
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the installer can install support for things like EJB3 so most likely contains
newer (and possibly more) jars than the zip.
You can just zip the installation directory created by the installer and have
your own zipped version.
JBoss 4.0 works very well with 1.5, in fact it requires it for some