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For us this turned out to be that we had cached html generated by the rails 3 app that had the ASCII-8BIT encoding, clearing all html caches fixed this.
To arrive at this, we first added this debug code:
# if you reuse this: ensure it matches the method in your version of rails # as the method is overwritten by this monkeypatch # config/initializers/debug_encoding_errors.rb ActiveSupport::SafeBuffer
|echo -e "machine api.heroku.com\n login $HEROKU_USER\n password $HEROKU_API_KEY\nmachine code.heroku.com\n login $HEROKU_USER\n password $HEROKU_API_KEY" > ~/.netrc && chmod 0600 /home/ubuntu/.netrc # We want to simply configure the API key, this seems easier than using the regular UI as that requires you to log in as a github user and assign yourself, etc.|