I've just built and manually deployed the pentaho.ear archive into my own JBoss application server (not the pre-packaged one).

One thing I would suggest is to merge the contents of the pentaho-styles.war into the pentaho.war file. In my opinion, it is a design flaw to have dependencies between separate web applications like this. One of the results is that the URL now has to be hardcoded into the pentaho.war web.xml file as a context-param, so that the links to images in the pentaho-styles.war work. This is pretty ugly and means that if we package pentaho along with our own server, we have to modify this parameter on every single individual deployment and hardcore the URL.