So, after some more days testing concurrent with an RealICE, we found out that every time the crash happens, the trace call leads us to a random mainloop/background function executing an return in assembly.
So the call stack must get invalid somehow. I have a high guess that this must be because of an interrupt.
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So I have now;
So the call stack must get invalid somehow. I have a high guess that this must be because of an interrupt.
Image may be NSFW.
Clik here to view.

So I have now;
- If no interrupts are enabled (handling all interrupt routines from mainloop) not ever an crash happens
- When enabling interrupts, a crash happens between several minutes to max 48 hours
- When I did a trace using RealIce, the crash happens when executing a return in a random background loop function
- Compiler (XC series) I enabled errata workaround = all
- The crash happens on all hardware boards (tested now more than 30 different devices, coming from seperate batches)
- Less likely that hardware has an error, since no error when not using interrupts.
- Interrupts are not using any unsafe access to mainloop variables.