I'm stumped. You need to view the modules/signatures in the tool and see if you have any "not required" modules. I seem to recall a bug where a COD comes up "not required" for RRT, but actually needs it. There is some class that is "required", but actually doesn't cause the COD to demand a signature. However, when run, the COD throws the exception on the offending class.
As I recall, there was a work-around to "force" the signature by including a (unnecessary) reference to one of the other "secure" classes.
Also, check this KB article and see if it rings any bells. http://www.blackberry.com/knowledgec...92675&vernum=0