This bug started as a dl() bugreport (http://bugs.php.net/bug.php?id=18383). 

Full dumps of the configure/compile sequence are there. They keep failing in the same place

Snaps I've tried:

php-4.0.3-zend2-alpha2
php4-200207181800
php4-200207201500 - as kalowsky@php.net requested

How I run configure:
[localhost:CWA/SSC/ssc_core_cvs_trunk] martin% make php-cli
cd
/Users/martin/Documents/CWA/SSC/ssc_core_cvs_trunk/local/src/php4-200207
181800 && \
./configure \
--prefix=/Users/martin/Documents/CWA/SSC/ssc_core_cvs_trunk/local/php4-2
00207181800 \
        --with-mysql=/sw \
        --enable-track-vars \
        --with-zlib-dir=/sw && \
make && make install

I have also tried without mysql, as markonen@php.net suggested. 

It always fails in teh same place. with the same message:
cc -DPHP_ATOM_INC
-I/Users/martin/Documents/CWA/SSC/ssc_core_cvs_trunk/local/src/php4-2002
07181800/include
-I/Users/martin/Documents/CWA/SSC/ssc_core_cvs_trunk/local/src/php4-2002
07181800/main
-I/Users/martin/Documents/CWA/SSC/ssc_core_cvs_trunk/local/src/php4-2002
07181800
-I/Users/martin/Documents/CWA/SSC/ssc_core_cvs_trunk/local/src/php4-2002
07181800/Zend -I/sw/include -I/sw/include/mysql
-I/Users/martin/Documents/CWA/SSC/ssc_core_cvs_trunk/local/src/php4-2002
07181800/ext/xml/expat  -no-cpp-precomp -no-cpp-precomp
-I/Users/martin/Documents/CWA/SSC/ssc_core_cvs_trunk/local/src/php4-2002
07181800/TSRM -g -O2  -L/sw/lib  -R /sw/lib ext/zlib/zlib.o
ext/zlib/zlib_fopen_wrapper.o ext/ctype/ctype.o
ext/mbstring/mbfilter_ja.o ext/mbstring/mbfilter_cn.o
ext/mbstring/mbfilter_tw.o ext/mbstring/mbfilter_kr.o
ext/mbstring/mbfilter_ru.o ext/mbstring/mbfilter.o
ext/mbstring/mbstring.o ext/mbstring/mbregex.o
ext/mbstring/php_mbregex.o ext/mysql/php_mysql.o ext/overload/overload.o
ext/pcre/pcrelib/maketables.o ext/pcre/pcrelib/get.o
ext/pcre/pcrelib/study.o ext/pcre/pcrelib/pcre.o ext/pcre/php_pcre.o
ext/posix/posix.o ext/session/session.o ext/session/mod_files.o
ext/session/mod_mm.o ext/session/mod_user.o ext/standard/array.o
ext/standard/base64.o ext/standard/basic_functions.o
ext/standard/browscap.o ext/standard/crc32.o ext/standard/crypt.o
ext/standard/cyr_convert.o ext/standard/datetime.o ext/standard/dir.o
ext/standard/dl.o ext/standard/dns.o ext/standard/exec.o
ext/standard/file.o ext/standard/filestat.o ext/standard/flock_compat.o
ext/standard/formatted_print.o ext/standard/fsock.o ext/standard/head.o
ext/standard/html.o ext/standard/image.o ext/standard/info.o
ext/standard/iptc.o ext/standard/lcg.o ext/standard/link.o
ext/standard/mail.o ext/standard/math.o ext/standard/md5.o
ext/standard/metaphone.o ext/standard/microtime.o ext/standard/pack.o
ext/standard/pageinfo.o ext/standard/parsedate.o
ext/standard/quot_print.o ext/standard/rand.o ext/standard/reg.o
ext/standard/soundex.o ext/standard/string.o ext/standard/scanf.o
ext/standard/syslog.o ext/standard/type.o ext/standard/uniqid.o
ext/standard/url.o ext/standard/url_scanner.o ext/standard/var.o
ext/standard/versioning.o ext/standard/assert.o ext/standard/strnatcmp.o
ext/standard/levenshtein.o ext/standard/incomplete_class.o
ext/standard/url_scanner_ex.o ext/standard/ftp_fopen_wrapper.o
ext/standard/http_fopen_wrapper.o ext/standard/php_fopen_wrapper.o
ext/standard/credits.o ext/standard/var_unserializer.o
ext/standard/ftok.o ext/standard/aggregation.o ext/tokenizer/tokenizer.o
ext/xml/xml.o ext/xml/expat/xmlparse.o ext/xml/expat/xmlrole.o
ext/xml/expat/xmltok.o regex/regcomp.o regex/regexec.o regex/regerror.o
regex/regfree.o TSRM/TSRM.o TSRM/tsrm_strtok_r.o TSRM/tsrm_virtual_cwd.o
main/main.o main/snprintf.o main/spprintf.o main/php_sprintf.o
main/safe_mode.o main/fopen_wrappers.o main/alloca.o main/php_ini.o
main/SAPI.o main/rfc1867.o main/php_content_types.o main/strlcpy.o
main/strlcat.o main/mergesort.o main/reentrancy.o main/php_variables.o
main/php_ticks.o main/streams.o main/network.o
main/php_open_temporary_file.o main/php_logos.o main/output.o
main/memory_streams.o main/user_streams.o Zend/zend_language_parser.o
Zend/zend_language_scanner.o Zend/zend_ini_parser.o
Zend/zend_ini_scanner.o Zend/zend_alloc.o Zend/zend_compile.o
Zend/zend_constants.o Zend/zend_dynamic_array.o Zend/zend_execute_API.o
Zend/zend_highlight.o Zend/zend_llist.o Zend/zend_opcode.o
Zend/zend_operators.o Zend/zend_ptr_stack.o Zend/zend_stack.o
Zend/zend_variables.o Zend/zend.o Zend/zend_API.o Zend/zend_extensions.o
Zend/zend_hash.o Zend/zend_list.o Zend/zend_indent.o
Zend/zend_builtin_functions.o Zend/zend_sprintf.o Zend/zend_ini.o
Zend/zend_qsort.o Zend/zend_multibyte.o Zend/zend_execute.o
sapi/cgi/cgi_main.o sapi/cgi/getopt.o main/internal_functions.o
-lmysqlclient -lz -lm  -o php
cc: unrecognized option `-R'
/usr/bin/ld: can't map file: /sw/lib ((os/kern) invalid argument)
make[1]: *** [php] Error 1
make: *** [php-cli] Error 2