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I figured this out. I had cause and effect mixed up. I thought the error was causing localization to fail. In reality, a localization failure was causing the error. Corrupted odom data was causing localization to fail. With odom data corruption fixed, localization is stable and this error hasn't returned.

The bad odom data was shifting the robot all the way off the map. It could be the rosmaster node isn't equipped to deal with that situation.

Closing this question.

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