fix(statusline): inject plan-usage telemetry via ephemeral CLI flag, never disk

Codeman's plan-usage chip wrote a statusLine.command into the case's
.claude/settings.local.json to receive Claude Code's rate_limits blob.
That file-based statusLine took precedence over the user's own
global/project statusline for ANY `claude` run in that directory,
including entirely outside Codeman, with no disclosure in the App
Settings UI (labeled only as a header-display toggle) and no way to
remove it once written (the removal code path was unreachable dead
code — nothing ever called it with false).

Replace the disk write with an EPHEMERAL `claude --settings
'{"statusLine":{...}}'` CLI flag, resolved fresh at spawn time
(resolveStatusLineCliCommand in hooks-config.ts) and merged with
effort/ultracode into one --settings object (buildClaudeSettingsFlag
in tmux-manager.ts, since Claude Code accepts only one --settings
flag). Never touches disk, so a plain `claude` run outside Codeman is
untouched. Self-healing: any legacy disk-written exporter from an
older build is stripped the first time a session starts in that
workspace again. Still respects a user's own hand-authored statusLine
(skips the flag entirely rather than overriding it).

Mid-fix bug found and fixed: the exporter's command legitimately
depends on $CODEMAN_SESSION_ID/$CODEMAN_API_URL/$CODEMAN_HOOK_SECRET_FILE
and an internal $INPUT, all meant to be expanded only when Claude Code
itself executes the statusline, using the pane's tmux-setenv'd
environment. Passing that text through --settings routed it through
execSync's own implicit /bin/sh -c first (tmux respawn-pane's
`bash -c "..."` wrapper) — POSIX double quotes don't suppress $
expansion, so those vars got expanded prematurely against the
server's own environment (unset there), producing malformed JSON that
printed as literal error text in the statusline. Fixed by writing the
exporter as a real, shared script file (ensureStatusLineExporterScript,
marker-versioned so stale copies self-heal) and passing only its bare
path via --settings — nothing for any intermediate shell to mangle.
Verified against a real Claude CLI on an isolated tmux socket, and via
direct execSync reproduction of the exact nested wrapping
createSession/respawnPane use.

A hard "never inject, even ephemerally" kill-switch was added and then
removed in the same pass: with the disk-leak fixed, disabling
injection only cost the plan-usage telemetry the feature exists to
provide, for no remaining benefit.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_015GyMnFWnUzc41TDeHg9juW

src/hooks-config.ts

@@ -31,7 +31,7 @@
 
 import { randomBytes } from 'node:crypto';
 import { existsSync } from 'node:fs';
-import { readFile, writeFile, mkdir, lstat, readdir, realpath, rename, unlink, rmdir } from 'node:fs/promises';
+import { readFile, writeFile, mkdir, lstat, readdir, realpath, rename, unlink, rmdir, chmod } from 'node:fs/promises';
 import { homedir } from 'node:os';
 import { join, dirname } from 'node:path';
 import { fileURLToPath } from 'node:url';
@@ -906,6 +906,115 @@ export async function applyStatusLineConfig(casePath: string, enabled: boolean):
   });
 }
 
+/**
+ * Version-agnostic marker embedded as a comment in the generated exporter
+ * SCRIPT (see ensureStatusLineExporterScript) — bump the numeric suffix
+ * whenever the script content changes so `ensureStatusLineExporterScript`'s
+ * content comparison rewrites stale copies on next use.
+ */
+const STATUSLINE_EXPORTER_SCRIPT_MARKER = 'CODEMAN_STATUSLINE_EXPORTER_V1';
+
+function statusLineExporterScriptContent(): string {
+  // Byte-identical logic to generateStatusLineCommand(), just as a real file
+  // instead of an inline string — see ensureStatusLineExporterScript for why
+  // that distinction matters (it is NOT cosmetic).
+  return (
+    `#!/bin/sh\n` +
+    `# ${STATUSLINE_EXPORTER_SCRIPT_MARKER} — auto-generated by Codeman; safe to delete, regenerated on demand.\n` +
+    `INPUT=$(cat 2>/dev/null || echo '{}')\n` +
+    `printf '{"sessionId":"%s","data":%s}' "$CODEMAN_SESSION_ID" "$INPUT" | ` +
+    `curl -sk -X POST "$CODEMAN_API_URL${STATUSLINE_MARKER}" ` +
+    `-H 'Content-Type: application/json' ` +
+    `-H "X-Codeman-Hook-Secret: $(cat "$CODEMAN_HOOK_SECRET_FILE" 2>/dev/null)" ` +
+    `--data @- 2>/dev/null || echo codeman\n`
+  );
+}
+
+/**
+ * Write (or refresh) the SHARED, single exporter script every claude session
+ * points its ephemeral --settings statusLine flag at, and return its absolute
+ * path. Idempotent: only rewrites when the marker-versioned content differs.
+ *
+ * This is the fix for a real bug found live 2026-08-31: the exporter's
+ * command string legitimately depends on `$CODEMAN_SESSION_ID`,
+ * `$CODEMAN_API_URL`, `$CODEMAN_HOOK_SECRET_FILE`, and its own internal
+ * `$INPUT` — all meant to be expanded ONLY when Claude Code itself finally
+ * executes the statusLine command, using the PANE's tmux-setenv'd
+ * environment. Passing that command as literal TEXT through
+ * `--settings '...'` routes it through this server's OWN spawn-time shell
+ * layers first (tmux respawn-pane's `bash -c "..."`, itself invoked via
+ * execSync's implicit `/bin/sh -c`) — and POSIX double quotes do NOT
+ * suppress `$` expansion, so those vars got expanded there and then, against
+ * the SERVER process's environment (where they are unset), producing a
+ * mangled curl call that posted malformed JSON and printed the server's raw
+ * error response as the statusline text itself. A bare file PATH has no `$`,
+ * quotes, or pipes for any of those intermediate shells to mangle — the
+ * script's own content (containing the real `$VAR`s) is never touched by a
+ * shell until Claude Code executes the file itself, at which point the
+ * pane's real environment is in scope. This mirrors the existing #208 fix in
+ * tmux-manager.ts (never embed a literal `$SHELL` meant for later
+ * expansion — resolve it, or in this case reference a file, instead).
+ */
+export async function ensureStatusLineExporterScript(): Promise<string> {
+  const scriptPath = dataPath('statusline-exporter.sh');
+  const desired = statusLineExporterScriptContent();
+  let current: string | null = null;
+  try {
+    current = await readFile(scriptPath, 'utf-8');
+  } catch {
+    // Doesn't exist yet.
+  }
+  if (current !== desired) {
+    await writeFile(scriptPath, desired);
+    await chmod(scriptPath, 0o755);
+  }
+  return scriptPath;
+}
+
+/**
+ * Resolve the statusLine command to pass as an EPHEMERAL `claude --settings`
+ * CLI flag for this one process (see buildClaudeSettingsFlag in
+ * tmux-manager.ts) — never written to disk. This supersedes the old
+ * applyStatusLineConfig(path, true) disk-write: a file-based statusLine
+ * leaked into any plain `claude` run in that directory outside Codeman
+ * entirely (it took precedence over the user's own global/project
+ * statusline with no disclosure and no way to remove it — found live
+ * 2026-08-31).
+ *
+ * Also self-heals: if an OLDER Codeman build already wrote its marked
+ * exporter into this workspace's settings.local.json, it is stripped here
+ * (isOurs-guarded, same as applyStatusLineConfig's removal branch) so every
+ * workspace migrates off the disk-based mechanism the first time a session
+ * starts there again — no manual cleanup required.
+ *
+ * Returns undefined when telemetry wasn't requested, or when the workspace
+ * already has its OWN hand-configured statusLine (never override a real one).
+ */
+export async function resolveStatusLineCliCommand(
+  casePath: string,
+  telemetryRequested: boolean
+): Promise<string | undefined> {
+  const settingsPath = join(casePath, '.claude', 'settings.local.json');
+  let userHasOwnStatusLine = false;
+  if (existsSync(settingsPath)) {
+    try {
+      const existing = JSON.parse(await readFile(settingsPath, 'utf-8'));
+      const current = existing.statusLine as { command?: unknown } | undefined;
+      if (current && typeof current.command === 'string') {
+        if (current.command.includes(STATUSLINE_MARKER)) {
+          await applyStatusLineConfig(casePath, false); // strip legacy disk-written exporter
+        } else {
+          userHasOwnStatusLine = true;
+        }
+      }
+    } catch {
+      // Malformed — leave it alone, same guard applyStatusLineConfig itself uses.
+    }
+  }
+  if (!telemetryRequested || userHasOwnStatusLine) return undefined;
+  return ensureStatusLineExporterScript();
+}
+
 // ─── Agent skill injection ───────────────────────────────────────────────────
 
 /**