Revision controls disappear after a few days of working perfectly.

How frustrating!
Reading your story there appear to be 2 major variables varying across your installations: the database (in particular the user permissions) and the theme.

The controls you mention (* List all revisions | * View | * Edit | * Unpublish this) are in fact tabs ("local tasks" in Drupal speak). These tend to be output in the page.tpl.php file of your theme via variables that are usually called $tabs/$tabs2 or $primary_links/$secondary_links. If you accidentally removed lines from your page.tpl.php file containing these variables then you won't see the tabs. However the disappearance would happen on every page that is meant to contain tabs, so this is not likely the case.

Which brings us to the database. A second reason why the tabs may not be there is because somehow the system feels that the logged-in user doesn't have the required permissions to those tabs. In the file revisioning.module you could print out the return value of the function _revision_tasks_menu_access_callback(...). It should be TRUE (1) for the tabs you want displayed. If it is FALSE (void or 0) all the time, then that means that access is denied and then at least we have narrowed it down.
If you don't feel comfortable using a PHP debugger, then here's a code snippet that will reveal the same.

First change the single occurrence of function _revision_tasks_menu_access_callback( to function _revision_tasks_menu_access_callback_internal(
Now add the following lines to the revisioning.module file (somewhere at the bottom is just fine):

function _revision_tasks_menu_access_callback($op, $node) {
  $result = _revision_tasks_menu_access_callback_internal($op, $node);
  drupal_set_message("access to '$op' of $node->title is: '$result'", 'warning', FALSE);
  return $result;
}

Now click around on the pages where you expect to see the tabs and check if you find a lot of access warning messages that end in '' (void) rather than '1'. This indicates that the Revisioning module feels that your system has been configured to deny access to the pages in question.

Naturally, as an administrator (uid=1) you should always see all tabs on all pages! Is this the case?

Hope this gives you some pointers to work with.

Rik

Yes user #1 has all privileges. This is hard-coded in Drupal core and does not require the database.
That's why this is so puzzling...

Hi pumpkinkid,
When you say 'menus' do you mean the navigational menu items or the tabs (i.e. local tasks)?
So is everything working for the administrator?
Can't see how any of the changes other than the inclusion of Smart tabs in Module Grants would have an effect on Nice Menus....
You did upgrade Revisioning to the latest dev when you updated Module Grants to the latest dev, didn't you?
A few things to try...
You say that your menus are screwed up. Could this be because you installed Smart menus in addition to Smart tabs?
I'd recommend to initially disable Smart menus. Maybe also try disabling Nice menus to isolate the error.
Enable Smart tabs but on the Administration >> Site configuration >> Smart tabs page leave the "Pages to include" text box empty (rather than having an * in there). Doing *should* just make the tabs on the Accessible content page behave properly, without adding any "Smart" behaviour.
Also: have you tried switching back to one of the default themes, like Blue Marine?
Finally, have a read of the Smart tabs FAQ (bottom of the project page).
Rik

Glad you sorted it out pumpkinkid!

"For published content, behave like core, that is OR as opposed to AND the access grants from multiple modules."
I am concerned though, does that check box cause issues with revisioning at all?

It may have an effect if you use Revisioning in combination with other modules that tinker with access grants, such as Workflow and TAC-Lite.... or in fact Content Access.... so beware...

Regarding the Revisioning tabs.... sounds like a bug I need to look at... .there shouldn't be two tabs active at the same time. You do mean that both of them are highlighted as being currently selected?

.... Is there a way to disable that functionality?

Yes on the Smart tabs configuration page Administer >> Site configuration >> Smart tabs you can specify on which pages the tabs should behave Smartly and which pages should be excluded.
If you don't want any Smart behaviour on any page (i.e. normal core behaviour) leave the "Pages included" text box empty (remove the asterisk).
If you do like it, then put in an asterisk but then put the path to the revisioning pages in the "Pages excluded" text box.

Thanks for the screen shot, pumpkinkid.
Created a new issue for this #631540: Two tabs highlighted as active at same time.
Closing this ticket as per your request.