Just a heads up in case anyone else runs into this problem....
After a hard drive failure, I had to rebuild a dev box over the holidays, and used the new 4.0.4. Had no problems installing on a fairly stock RedHat 6.2 system with MySQL, and many of the goodies... Ran into problems doing an upgrade to 4.0.4 on two other separate machines... different versions of php4... same error on starting Apache... undefined symbol relating to an SSL_RSA blah, blah... Tried on another system which didn't have php yet, same 6.2 install, and again no problems.
It would seem, that something in 4.0.4 is requiring a clean install with no previous PHP... will be removing older php and testing this on one of the failed machines later this week... will post results and bug if it pans out