chore: version packages

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

CHANGELOG.md

@@ -1,5 +1,26 @@
 # aicodeman
 
+## 0.5.4
+
+### Patch Changes
+
+- Fix terminal flicker regression — re-add server-side DEC 2026 synchronized output wrapping around batched terminal data. Ink spinner frames (cursor-up + redraw cycles) do not emit their own DEC 2026 markers, so without the server wrapper each partial cursor update rendered individually causing visible flicker. Also: extract SSE stream management, session listener wiring, and respawn event wiring from server.ts into dedicated modules; deduplicate error message extraction across 7 files with shared getErrorMessage() helper; update SSE event count in CLAUDE.md (106 → 117).
+
+## 0.5.3
+
+### Patch Changes
+
+- Readability refactor across 12 core files, extracting ~35 helper methods to reduce duplication:
+  - state-store: extract serializeState(), split assembleStateJson() into focused sub-methods
+  - session: extract \_resetBuffers() (3x dedup), \_clearAllTimers() (10 timer cleanups), \_handleJsonMessage()
+  - ralph-tracker: extract completeAllTodos() (4x dedup), emitValidationWarning(), named similarity constants
+  - subagent-watcher: extract markSubagentAsCompleted(), extractFirstTextContent(), emitToolResult(), findOldestInactiveAgent()
+  - respawn-controller: extract recoveryResetToWatching(), canAutoAccept(), formatRemainingSeconds(), validatePositiveTimeout()
+  - tmux-manager: replace 15 path.includes() with UNSAFE_PATH_CHARS regex, extract buildEnvExports/buildPathExport/\_configureOpenCode helpers
+  - session-auto-ops: extract executeWhenIdle() shared retry helper, convert to options object, add validateThreshold()
+  - app.js: add \_clearTimer() (11 call sites), \_isStaleSelect(), keyboard shortcut lookup table, \_cleanupPreviousSession(), \_resetAllAppState()
+  - route-helpers: add readJsonConfig() (5 inline patterns replaced), validateSessionFilePath() (2 duplicated blocks replaced)
+
 ## 0.5.2
 
 ### Patch Changes

CLAUDE.md

@@ -6,7 +6,7 @@ This file provides guidance to Claude Code (claude.ai/code) when working with co
 
 | Task | Command |
 |------|---------|
-| Dev server | `npx tsx src/index.ts web` |
+| Dev server | `npm run dev` (or `npx tsx src/index.ts web`) |
 | Type check | `tsc --noEmit` |
 | Lint | `npm run lint` (fix: `npm run lint:fix`) |
 | Format | `npm run format` (check: `npm run format:check`) |
@@ -52,7 +52,7 @@ When user says "COM":
 4. **Sync CLAUDE.md version**: Update the `**Version**` line below to match the new version from `package.json`
 5. **Commit and deploy**: `git add -A && git commit -m "chore: version packages" && git push && npm run build && systemctl --user restart codeman-web`
 
-**Version**: 0.5.2 (must match `package.json`)
+**Version**: 0.5.4 (must match `package.json`)
 
 ## Project Overview
 
@@ -78,7 +78,7 @@ Codeman is a Claude Code session manager with web interface and autonomous Ralph
 | Production start | `npm run start` |
 | Production logs | `journalctl --user -u codeman-web -f` |
 
-**CI**: `.github/workflows/ci.yml` runs `typecheck`, `lint`, `format:check` on push to master (Node 22). Tests excluded (they spawn tmux).
+**CI**: `.github/workflows/ci.yml` runs `typecheck`, `lint`, `format:check` on push to master/main and on PRs (Node 22). Tests excluded (they spawn tmux).
 
 **Code style**: Prettier (`singleQuote: true`, `printWidth: 120`, `trailingComma: "es5"`). ESLint flat config (`eslint.config.js`) allows `no-console`, warns on `@typescript-eslint/no-explicit-any`. Ignores: `app.js`, `scripts/**/*.mjs`, `src/web/public/vendor/**`, `tools/**`, `remotion/**`.
 
@@ -167,7 +167,7 @@ Frontend JS modules have `@fileoverview` with `@dependency`/`@loadorder` tags. L
 
 ### SSE Event Registry
 
-~106 event types in `src/web/sse-events.ts` (backend) and `SSE_EVENTS` in `constants.js` (frontend). Both must be kept in sync.
+~117 event types in `src/web/sse-events.ts` (backend) and `SSE_EVENTS` in `constants.js` (frontend). Both must be kept in sync.
 
 ### API Routes
 

package.json

@@ -1,6 +1,6 @@
 {
   "name": "aicodeman",
-  "version": "0.5.2",
+  "version": "0.5.4",
   "description": "The missing control plane for AI coding agents - run 20 autonomous agents with real-time monitoring and session persistence",
   "type": "module",
   "main": "dist/index.js",

src/ai-checker-base.ts

@@ -30,6 +30,7 @@ import { join } from 'node:path';
 import { EventEmitter } from 'node:events';
 import { getAugmentedPath, ANSI_ESCAPE_PATTERN_SIMPLE } from './utils/index.js';
 import { AI_CHECK_MAX_BACKOFF_MS } from './config/ai-defaults.js';
+import { getErrorMessage } from './types.js';
 
 // ========== Security Validation ==========
 
@@ -293,7 +294,7 @@ export abstract class AiCheckerBase<
       this.emit('checkCompleted', result);
       return result;
     } catch (err) {
-      const errorMsg = err instanceof Error ? err.message : String(err);
+      const errorMsg = getErrorMessage(err);
       this.handleError(errorMsg);
       const result = this.createErrorResult(errorMsg, Date.now() - this.checkStartTime);
       this.emit('checkFailed', errorMsg);
@@ -412,9 +413,7 @@ export abstract class AiCheckerBase<
       });
       muxProcess.unref();
     } catch (err) {
-      throw new Error(
-        `Failed to spawn ${this.checkDescription} tmux session: ${err instanceof Error ? err.message : String(err)}`
-      );
+      throw new Error(`Failed to spawn ${this.checkDescription} tmux session: ${getErrorMessage(err)}`);
     }
 
     // Poll the temp file for completion

src/bash-tool-parser.ts

@@ -470,120 +470,91 @@ export class BashToolParser extends EventEmitter<BashToolParserEvents> {
    * Process a single pre-stripped line of terminal output.
    */
   private processCleanLine(cleanLine: string): void {
-    // Check for tool start
+    if (this._handleToolStart(cleanLine)) return;
+    if (this._handleToolCompletion(cleanLine)) return;
+    if (this._handleTextCommand(cleanLine)) return;
+    this._handleLogFileMention(cleanLine);
+  }
+
+  private _handleToolStart(cleanLine: string): boolean {
     const startMatch = cleanLine.match(BASH_TOOL_START_PATTERN);
-    if (startMatch) {
-      const command = startMatch[1];
-      const timeout = startMatch[2]?.trim();
+    if (!startMatch) return false;
 
-      // Check if this is a file-viewing command
-      if (this.isFileViewerCommand(command)) {
-        const filePaths = this.extractFilePaths(command);
+    const command = startMatch[1];
+    const timeout = startMatch[2]?.trim();
 
-        // Skip if any file path is already tracked (cross-pattern dedup)
-        if (filePaths.some((fp) => this.isFilePathTracked(fp))) {
-          return;
-        }
+    if (!this.isFileViewerCommand(command)) return true;
 
-        if (filePaths.length > 0) {
-          const tool: ActiveBashTool = {
-            id: uuidv4(),
-            command,
-            filePaths,
-            timeout,
-            startedAt: Date.now(),
-            status: 'running',
-            sessionId: this._sessionId,
-          };
+    const filePaths = this.extractFilePaths(command);
 
-          // Enforce max tools limit
-          if (this._activeTools.size >= MAX_ACTIVE_TOOLS) {
-            // Remove oldest tool (O(n) min-scan instead of O(n log n) sort)
-            let oldestKey: string | undefined;
-            let oldestTime = Infinity;
-            for (const [key, entry] of this._activeTools) {
-              if (entry.startedAt < oldestTime) {
-                oldestTime = entry.startedAt;
-                oldestKey = key;
-              }
-            }
-            if (oldestKey) {
-              this._activeTools.delete(oldestKey);
-            }
+    // Skip if any file path is already tracked (cross-pattern dedup)
+    if (filePaths.some((fp) => this.isFilePathTracked(fp))) return true;
+
+    if (filePaths.length > 0) {
+      const tool = this._createActiveTool(command, filePaths, 'running', timeout);
+
+      // Enforce max tools limit
+      if (this._activeTools.size >= MAX_ACTIVE_TOOLS) {
+        // Remove oldest tool (O(n) min-scan instead of O(n log n) sort)
+        let oldestKey: string | undefined;
+        let oldestTime = Infinity;
+        for (const [key, entry] of this._activeTools) {
+          if (entry.startedAt < oldestTime) {
+            oldestTime = entry.startedAt;
+            oldestKey = key;
           }
-
-          this._activeTools.set(tool.id, tool);
-          this._lastToolId = tool.id;
-
-          this.emit('toolStart', tool);
-          this.scheduleUpdate();
         }
-      }
-      return;
-    }
-
-    // Check for tool completion
-    if (TOOL_COMPLETION_PATTERN.test(cleanLine) && this._lastToolId) {
-      const tool = this._activeTools.get(this._lastToolId);
-      if (tool && tool.status === 'running') {
-        tool.status = 'completed';
-        this.emit('toolEnd', tool);
-        this.scheduleUpdate();
-
-        // Remove completed tool after a short delay to allow UI to show completion
-        this.cleanup.setTimeout(
-          () => {
-            if (this._destroyed) return;
-            this._activeTools.delete(tool.id);
-            this.scheduleUpdate();
-          },
-          2000,
-          { description: 'auto-remove completed tool' }
-        );
-      }
-      this._lastToolId = null;
-      return;
-    }
-
-    // Fallback: Check for command suggestions in plain text (e.g., "tail -f /tmp/file.log")
-    const textCmdMatch = cleanLine.match(TEXT_COMMAND_PATTERN);
-    if (textCmdMatch) {
-      const filePath = textCmdMatch[2];
-
-      // Create a suggestion tool (marked as 'suggestion' status)
-      const tool: ActiveBashTool = {
-        id: uuidv4(),
-        command: cleanLine.trim(),
-        filePaths: [filePath],
-        timeout: undefined,
-        startedAt: Date.now(),
-        status: 'running', // Shows as clickable
-        sessionId: this._sessionId,
-      };
-
-      // Don't add if file path already tracked (cross-pattern dedup)
-      if (this.isFilePathTracked(filePath)) {
-        return;
+        if (oldestKey) {
+          this._activeTools.delete(oldestKey);
+        }
       }
 
       this._activeTools.set(tool.id, tool);
+      this._lastToolId = tool.id;
+
       this.emit('toolStart', tool);
       this.scheduleUpdate();
-
-      // Auto-remove suggestions after 30 seconds
-      this.cleanup.setTimeout(
-        () => {
-          if (this._destroyed) return;
-          this._activeTools.delete(tool.id);
-          this.scheduleUpdate();
-        },
-        30000,
-        { description: 'auto-remove suggestion tool' }
-      );
-      return;
     }
 
-    // Last fallback: Check for log file paths mentioned anywhere in the line
+    return true;
+  }
+
+  private _handleToolCompletion(cleanLine: string): boolean {
+    if (!TOOL_COMPLETION_PATTERN.test(cleanLine) || !this._lastToolId) return false;
+
+    const tool = this._activeTools.get(this._lastToolId);
+    if (tool && tool.status === 'running') {
+      tool.status = 'completed';
+      this.emit('toolEnd', tool);
+      this.scheduleUpdate();
+
+      this._scheduleAutoRemove(tool.id, 2000, 'auto-remove completed tool');
+    }
+    this._lastToolId = null;
+    return true;
+  }
+
+  private _handleTextCommand(cleanLine: string): boolean {
+    const textCmdMatch = cleanLine.match(TEXT_COMMAND_PATTERN);
+    if (!textCmdMatch) return false;
+
+    const filePath = textCmdMatch[2];
+
+    // Don't add if file path already tracked (cross-pattern dedup)
+    if (this.isFilePathTracked(filePath)) return true;
+
+    const tool = this._createActiveTool(cleanLine.trim(), [filePath], 'running');
+
+    this._activeTools.set(tool.id, tool);
+    this.emit('toolStart', tool);
+    this.scheduleUpdate();
+
+    // Auto-remove suggestions after 30 seconds
+    this._scheduleAutoRemove(tool.id, 30000, 'auto-remove suggestion tool');
+    return true;
+  }
+
+  private _handleLogFileMention(cleanLine: string): void {
     LOG_FILE_MENTION_PATTERN.lastIndex = 0;
     let logMatch;
     while ((logMatch = LOG_FILE_MENTION_PATTERN.exec(cleanLine)) !== null) {
@@ -595,33 +566,46 @@ export class BashToolParser extends EventEmitter<BashToolParserEvents> {
       // Skip if file path already tracked (cross-pattern dedup)
       if (this.isFilePathTracked(filePath)) continue;
 
-      const tool: ActiveBashTool = {
-        id: uuidv4(),
-        command: `View: ${filePath}`,
-        filePaths: [filePath],
-        timeout: undefined,
-        startedAt: Date.now(),
-        status: 'running',
-        sessionId: this._sessionId,
-      };
+      const tool = this._createActiveTool(`View: ${filePath}`, [filePath], 'running');
 
       this._activeTools.set(tool.id, tool);
       this.emit('toolStart', tool);
       this.scheduleUpdate();
 
       // Auto-remove after 60 seconds
-      this.cleanup.setTimeout(
-        () => {
-          if (this._destroyed) return;
-          this._activeTools.delete(tool.id);
-          this.scheduleUpdate();
-        },
-        60000,
-        { description: 'auto-remove log file tool' }
-      );
+      this._scheduleAutoRemove(tool.id, 60000, 'auto-remove log file tool');
     }
   }
 
+  private _createActiveTool(
+    command: string,
+    filePaths: string[],
+    status: ActiveBashTool['status'],
+    timeout?: string
+  ): ActiveBashTool {
+    return {
+      id: uuidv4(),
+      command,
+      filePaths,
+      timeout,
+      startedAt: Date.now(),
+      status,
+      sessionId: this._sessionId,
+    };
+  }
+
+  private _scheduleAutoRemove(toolId: string, delayMs: number, description: string): void {
+    this.cleanup.setTimeout(
+      () => {
+        if (this._destroyed) return;
+        this._activeTools.delete(toolId);
+        this.scheduleUpdate();
+      },
+      delayMs,
+      { description }
+    );
+  }
+
   /**
    * Check if a command is a file-viewing command worth tracking.
    */

src/file-stream-manager.ts

@@ -16,6 +16,7 @@ import { existsSync, statSync, realpathSync } from 'node:fs';
 import { resolve, relative, isAbsolute } from 'node:path';
 import { homedir } from 'node:os';
 import { EventEmitter } from 'node:events';
+import { getErrorMessage } from './types.js';
 import { CLEANUP_CHECK_INTERVAL_MS, INACTIVITY_TIMEOUT_MS } from './config/server-timing.js';
 
 // ========== Configuration Constants ==========
@@ -172,10 +173,7 @@ export class FileStreamManager extends EventEmitter {
       }
     } catch (err) {
       const errorCode = err instanceof Error && 'code' in err ? (err as NodeJS.ErrnoException).code : 'UNKNOWN';
-      console.warn(
-        `[FileStreamManager] Failed to stat file "${absolutePath}" (${errorCode}):`,
-        err instanceof Error ? err.message : String(err)
-      );
+      console.warn(`[FileStreamManager] Failed to stat file "${absolutePath}" (${errorCode}):`, getErrorMessage(err));
       return { success: false, error: 'File not found or not accessible' };
     }
 

src/orchestrator-loop.ts

@@ -499,27 +499,34 @@ export class OrchestratorLoop extends EventEmitter {
     }
   }
 
-  private handleTaskCompleted(queueTaskId: string): void {
+  private _finalizeTask(queueTaskId: string, status: 'completed' | 'failed', error?: string): OrchestratorTask | null {
     const orchTask = this.findOrchestratorTaskByQueueId(queueTaskId);
+    if (!orchTask) return null;
+
+    orchTask.status = status;
+    if (status === 'completed') {
+      orchTask.completedAt = Date.now();
+      this.stats.totalTasksCompleted++;
+    } else {
+      orchTask.error = error ?? null;
+      this.stats.totalTasksFailed++;
+    }
+    this.persist();
+    return orchTask;
+  }
+
+  private handleTaskCompleted(queueTaskId: string): void {
+    const orchTask = this._finalizeTask(queueTaskId, 'completed');
     if (!orchTask) return;
 
-    orchTask.status = 'completed';
-    orchTask.completedAt = Date.now();
-    this.stats.totalTasksCompleted++;
-    this.persist();
     this.emit('taskCompleted', orchTask);
-
     this.checkPhaseCompletion();
   }
 
   private handleTaskFailed(queueTaskId: string, error: string): void {
-    const orchTask = this.findOrchestratorTaskByQueueId(queueTaskId);
+    const orchTask = this._finalizeTask(queueTaskId, 'failed', error);
     if (!orchTask) return;
 
-    orchTask.status = 'failed';
-    orchTask.error = error;
-    this.stats.totalTasksFailed++;
-    this.persist();
     this.emit('taskFailed', orchTask, error);
 
     // Check if we should retry the task or fail the phase
@@ -553,19 +560,20 @@ export class OrchestratorLoop extends EventEmitter {
     }, this.config.phaseTimeoutMs);
   }
 
+  private _clearTimer(
+    timerKey: 'phasePollTimer' | 'phaseTimeoutTimer' | 'postPhaseTimer',
+    clearFn: typeof clearInterval | typeof clearTimeout
+  ): void {
+    if (this[timerKey]) {
+      clearFn(this[timerKey]);
+      this[timerKey] = null;
+    }
+  }
+
   private clearPhasePoll(): void {
-    if (this.phasePollTimer) {
-      clearInterval(this.phasePollTimer);
-      this.phasePollTimer = null;
-    }
-    if (this.phaseTimeoutTimer) {
-      clearTimeout(this.phaseTimeoutTimer);
-      this.phaseTimeoutTimer = null;
-    }
-    if (this.postPhaseTimer) {
-      clearTimeout(this.postPhaseTimer);
-      this.postPhaseTimer = null;
-    }
+    this._clearTimer('phasePollTimer', clearInterval);
+    this._clearTimer('phaseTimeoutTimer', clearTimeout);
+    this._clearTimer('postPhaseTimer', clearTimeout);
   }
 
   private pollPhaseStatus(phase: OrchestratorPhase): void {

src/orchestrator-verifier.ts

@@ -20,7 +20,13 @@
  */
 
 import type { Session } from './session.js';
-import type { OrchestratorPhase, OrchestratorConfig, VerificationResult, VerificationCheck } from './types.js';
+import {
+  getErrorMessage,
+  type OrchestratorPhase,
+  type OrchestratorConfig,
+  type VerificationResult,
+  type VerificationCheck,
+} from './types.js';
 
 // ═══════════════════════════════════════════════════════════════
 // Constants
@@ -111,7 +117,7 @@ export class OrchestratorVerifier {
           type: 'test_command',
           description: `Run: ${command}`,
           passed: false,
-          output: err instanceof Error ? err.message : String(err),
+          output: getErrorMessage(err),
         });
       }
     }
@@ -164,7 +170,7 @@ export class OrchestratorVerifier {
         type: 'ai_review',
         description: `AI review of "${phase.name}"`,
         passed: false,
-        output: `AI review timed out or failed: ${err instanceof Error ? err.message : String(err)}`,
+        output: `AI review timed out or failed: ${getErrorMessage(err)}`,
       };
     }
   }

src/plan-orchestrator.ts

@@ -20,7 +20,7 @@ import type { TerminalMultiplexer } from './mux-interface.js';
 import { existsSync, mkdirSync, writeFileSync } from 'node:fs';
 import { join } from 'node:path';
 import { RESEARCH_AGENT_PROMPT, PLANNER_PROMPT } from './prompts/index.js';
-import type { PlanItem } from './types.js';
+import { getErrorMessage, type PlanItem } from './types.js';
 
 // Re-export for backward compatibility
 export type { PlanItem };
@@ -231,6 +231,49 @@ export class PlanOrchestrator {
     return md;
   }
 
+  private _extractJsonFromResponse(response: string): string | null {
+    let jsonMatch = response.match(/```(?:json)?\s*(\{[\s\S]*?\})\s*```/);
+    if (jsonMatch) {
+      jsonMatch = [jsonMatch[1]]; // Use captured group (inside code block)
+    } else {
+      jsonMatch = response.match(/\{[\s\S]*\}/);
+    }
+    return jsonMatch ? jsonMatch[0] : null;
+  }
+
+  private _emitAgentFailure(
+    onSubagent: SubagentCallback | undefined,
+    agentId: string,
+    agentType: 'research' | 'planner',
+    model: string,
+    error: string,
+    durationMs: number
+  ): void {
+    onSubagent?.({
+      type: 'failed',
+      agentId,
+      agentType,
+      model,
+      status: 'failed',
+      error,
+      durationMs,
+    });
+  }
+
+  private _formatResearchSection(
+    parts: string[],
+    title: string,
+    items: unknown[],
+    formatter: (item: unknown) => string[]
+  ): void {
+    if (items.length === 0) return;
+    parts.push(title);
+    for (const item of items.slice(0, 5)) {
+      parts.push(...formatter(item));
+    }
+    parts.push('');
+  }
+
   async cancel(): Promise<void> {
     this.cancelled = true;
     // Stop all running sessions and await cleanup to prevent PTY process leaks
@@ -312,7 +355,7 @@ export class PlanOrchestrator {
     } catch (err) {
       return {
         success: false,
-        error: err instanceof Error ? err.message : String(err),
+        error: getErrorMessage(err),
       };
     }
   }
@@ -322,32 +365,23 @@ export class PlanOrchestrator {
 
     const parts: string[] = ['## Research Context\n'];
 
-    if (research.findings.externalResources.length > 0) {
-      parts.push('### External Resources');
-      for (const r of research.findings.externalResources.slice(0, 5)) {
-        parts.push(`- ${r.title}${r.url ? ` (${r.url})` : ''}`);
-        if (r.keyInsights.length > 0) {
-          parts.push(`  Key insights: ${r.keyInsights.slice(0, 3).join(', ')}`);
-        }
+    this._formatResearchSection(parts, '### External Resources', research.findings.externalResources, (item) => {
+      const r = item as ResearchResult['findings']['externalResources'][number];
+      const lines = [`- ${r.title}${r.url ? ` (${r.url})` : ''}`];
+      if (r.keyInsights.length > 0) {
+        lines.push(`  Key insights: ${r.keyInsights.slice(0, 3).join(', ')}`);
       }
-      parts.push('');
-    }
+      return lines;
+    });
 
-    if (research.findings.codebasePatterns.length > 0) {
-      parts.push('### Existing Codebase Patterns');
-      for (const p of research.findings.codebasePatterns.slice(0, 5)) {
-        parts.push(`- ${p.pattern} at ${p.location}`);
-      }
-      parts.push('');
-    }
+    this._formatResearchSection(parts, '### Existing Codebase Patterns', research.findings.codebasePatterns, (item) => {
+      const p = item as ResearchResult['findings']['codebasePatterns'][number];
+      return [`- ${p.pattern} at ${p.location}`];
+    });
 
-    if (research.findings.technicalRecommendations.length > 0) {
-      parts.push('### Recommendations');
-      for (const r of research.findings.technicalRecommendations.slice(0, 5)) {
-        parts.push(`- ${r}`);
-      }
-      parts.push('');
-    }
+    this._formatResearchSection(parts, '### Recommendations', research.findings.technicalRecommendations, (item) => [
+      `- ${item as string}`,
+    ]);
 
     return parts.join('\n');
   }
@@ -414,18 +448,20 @@ export class PlanOrchestrator {
 
       const durationMs = Date.now() - startTime;
 
-      // Extract JSON from response
-      const jsonMatch = response.match(/\{[\s\S]*\}/);
-      if (!jsonMatch) {
-        onSubagent?.({
-          type: 'failed',
-          agentId,
-          agentType: 'research',
-          model: this.researchModel,
-          status: 'failed',
-          error: 'No JSON found',
-          durationMs,
-        });
+      console.log(
+        `[PlanOrchestrator] Research response length: ${response.length}, first 500 chars:`,
+        response.substring(0, 500)
+      );
+
+      // Extract JSON from response — try multiple strategies
+      const jsonStr = this._extractJsonFromResponse(response);
+
+      if (!jsonStr) {
+        console.error(
+          `[PlanOrchestrator] No JSON found in research response. Full response:`,
+          response.substring(0, 2000)
+        );
+        this._emitAgentFailure(onSubagent, agentId, 'research', this.researchModel, 'No JSON found', durationMs);
         return {
           success: false,
           findings: {
@@ -441,17 +477,9 @@ export class PlanOrchestrator {
         };
       }
 
-      const parsed = tryParseJSON(jsonMatch[0]);
+      const parsed = tryParseJSON(jsonStr);
       if (!parsed.success) {
-        onSubagent?.({
-          type: 'failed',
-          agentId,
-          agentType: 'research',
-          model: this.researchModel,
-          status: 'failed',
-          error: parsed.error,
-          durationMs,
-        });
+        this._emitAgentFailure(onSubagent, agentId, 'research', this.researchModel, parsed.error!, durationMs);
         return {
           success: false,
           findings: {
@@ -495,16 +523,8 @@ export class PlanOrchestrator {
       return result;
     } catch (err) {
       const durationMs = Date.now() - startTime;
-      const error = err instanceof Error ? err.message : String(err);
-      onSubagent?.({
-        type: 'failed',
-        agentId,
-        agentType: 'research',
-        model: this.researchModel,
-        status: 'failed',
-        error,
-        durationMs,
-      });
+      const error = getErrorMessage(err);
+      this._emitAgentFailure(onSubagent, agentId, 'research', this.researchModel, error, durationMs);
       return {
         success: false,
         findings: {
@@ -587,32 +607,26 @@ export class PlanOrchestrator {
 
       const durationMs = Date.now() - startTime;
 
-      // Extract JSON from response
-      const jsonMatch = response.match(/\{[\s\S]*\}/);
-      if (!jsonMatch) {
-        onSubagent?.({
-          type: 'failed',
-          agentId,
-          agentType: 'planner',
-          model: this.plannerModel,
-          status: 'failed',
-          error: 'No JSON found',
-          durationMs,
-        });
+      console.log(
+        `[PlanOrchestrator] Planner response length: ${response.length}, first 500 chars:`,
+        response.substring(0, 500)
+      );
+
+      // Extract JSON from response — try multiple strategies
+      const jsonStr = this._extractJsonFromResponse(response);
+
+      if (!jsonStr) {
+        console.error(
+          `[PlanOrchestrator] No JSON found in planner response. Full response:`,
+          response.substring(0, 2000)
+        );
+        this._emitAgentFailure(onSubagent, agentId, 'planner', this.plannerModel, 'No JSON found', durationMs);
         return { success: false, error: 'No JSON in response' };
       }
 
-      const parsed = tryParseJSON(jsonMatch[0]);
+      const parsed = tryParseJSON(jsonStr);
       if (!parsed.success) {
-        onSubagent?.({
-          type: 'failed',
-          agentId,
-          agentType: 'planner',
-          model: this.plannerModel,
-          status: 'failed',
-          error: parsed.error,
-          durationMs,
-        });
+        this._emitAgentFailure(onSubagent, agentId, 'planner', this.plannerModel, parsed.error!, durationMs);
         return { success: false, error: parsed.error };
       }
 
@@ -637,16 +651,8 @@ export class PlanOrchestrator {
       return { success: true, items, gaps, warnings };
     } catch (err) {
       const durationMs = Date.now() - startTime;
-      const error = err instanceof Error ? err.message : String(err);
-      onSubagent?.({
-        type: 'failed',
-        agentId,
-        agentType: 'planner',
-        model: this.plannerModel,
-        status: 'failed',
-        error,
-        durationMs,
-      });
+      const error = getErrorMessage(err);
+      this._emitAgentFailure(onSubagent, agentId, 'planner', this.plannerModel, error, durationMs);
       return { success: false, error };
     } finally {
       // Always clean up session and progress interval — centralizing here

src/ralph-status-parser.ts

@@ -91,6 +91,67 @@ const COMPLETION_INDICATOR_PATTERNS = [
   /project\s+(?:is\s+)?(?:completed?|done|finished)/i,
 ];
 
+interface FieldParser<T> {
+  pattern: RegExp;
+  field: keyof RalphStatusBlock;
+  validate: (value: string) => boolean;
+  transform: (value: string) => T;
+  errorMsg: (value: string) => string;
+}
+
+const FIELD_PARSERS: FieldParser<RalphStatusValue | RalphTestsStatus | RalphWorkType | number | boolean | string>[] = [
+  {
+    pattern: RALPH_STATUS_FIELD_PATTERN,
+    field: 'status',
+    validate: (v) => ['IN_PROGRESS', 'COMPLETE', 'BLOCKED'].includes(v.toUpperCase()),
+    transform: (v) => v.toUpperCase() as RalphStatusValue,
+    errorMsg: (v) => `Invalid STATUS value: "${v}". Expected: IN_PROGRESS, COMPLETE, or BLOCKED`,
+  },
+  {
+    pattern: RALPH_TASKS_COMPLETED_PATTERN,
+    field: 'tasksCompletedThisLoop',
+    validate: (v) => !Number.isNaN(parseInt(v, 10)) && parseInt(v, 10) >= 0,
+    transform: (v) => parseInt(v, 10),
+    errorMsg: (v) => `Invalid TASKS_COMPLETED_THIS_LOOP value: "${v}". Expected: non-negative integer`,
+  },
+  {
+    pattern: RALPH_FILES_MODIFIED_PATTERN,
+    field: 'filesModified',
+    validate: (v) => !Number.isNaN(parseInt(v, 10)) && parseInt(v, 10) >= 0,
+    transform: (v) => parseInt(v, 10),
+    errorMsg: (v) => `Invalid FILES_MODIFIED value: "${v}". Expected: non-negative integer`,
+  },
+  {
+    pattern: RALPH_TESTS_STATUS_PATTERN,
+    field: 'testsStatus',
+    validate: (v) => ['PASSING', 'FAILING', 'NOT_RUN'].includes(v.toUpperCase()),
+    transform: (v) => v.toUpperCase() as RalphTestsStatus,
+    errorMsg: (v) => `Invalid TESTS_STATUS value: "${v}". Expected: PASSING, FAILING, or NOT_RUN`,
+  },
+  {
+    pattern: RALPH_WORK_TYPE_PATTERN,
+    field: 'workType',
+    validate: (v) => ['IMPLEMENTATION', 'TESTING', 'DOCUMENTATION', 'REFACTORING'].includes(v.toUpperCase()),
+    transform: (v) => v.toUpperCase() as RalphWorkType,
+    errorMsg: (v) =>
+      `Invalid WORK_TYPE value: "${v}". Expected: IMPLEMENTATION, TESTING, DOCUMENTATION, or REFACTORING`,
+  },
+  {
+    pattern: RALPH_EXIT_SIGNAL_PATTERN,
+    field: 'exitSignal',
+    validate: () => true,
+    transform: (v) => v.toLowerCase() === 'true',
+    errorMsg: () => '',
+  },
+  {
+    pattern: RALPH_RECOMMENDATION_PATTERN,
+    field: 'recommendation',
+    validate: () => true,
+    transform: (v) => v.trim(),
+    errorMsg: () => '',
+  },
+];
+
 /**
  * RalphStatusParser - Parses RALPH_STATUS blocks and manages circuit breaker.
  *
@@ -303,85 +364,21 @@ export class RalphStatusParser extends EventEmitter {
       const trimmedLine = line.trim();
       if (!trimmedLine) continue;
 
-      // Track whether this line matched any known field
       let matched = false;
 
-      // STATUS field (required)
-      const statusMatch = trimmedLine.match(RALPH_STATUS_FIELD_PATTERN);
-      if (statusMatch) {
-        const value = statusMatch[1].toUpperCase();
-        if (['IN_PROGRESS', 'COMPLETE', 'BLOCKED'].includes(value)) {
-          block.status = value as RalphStatusValue;
-        } else {
-          parseErrors.push(`Invalid STATUS value: "${value}". Expected: IN_PROGRESS, COMPLETE, or BLOCKED`);
+      for (const parser of FIELD_PARSERS) {
+        const match = trimmedLine.match(parser.pattern);
+        if (match) {
+          const rawValue = match[1];
+          if (parser.validate(rawValue)) {
+            // eslint-disable-next-line @typescript-eslint/no-explicit-any
+            (block as any)[parser.field] = parser.transform(rawValue);
+          } else {
+            parseErrors.push(parser.errorMsg(rawValue));
+          }
+          matched = true;
+          break;
         }
-        matched = true;
-      }
-
-      // TASKS_COMPLETED_THIS_LOOP field
-      const tasksMatch = trimmedLine.match(RALPH_TASKS_COMPLETED_PATTERN);
-      if (tasksMatch) {
-        const value = parseInt(tasksMatch[1], 10);
-        if (!Number.isNaN(value) && value >= 0) {
-          block.tasksCompletedThisLoop = value;
-        } else {
-          parseErrors.push(
-            `Invalid TASKS_COMPLETED_THIS_LOOP value: "${tasksMatch[1]}". Expected: non-negative integer`
-          );
-        }
-        matched = true;
-      }
-
-      // FILES_MODIFIED field
-      const filesMatch = trimmedLine.match(RALPH_FILES_MODIFIED_PATTERN);
-      if (filesMatch) {
-        const value = parseInt(filesMatch[1], 10);
-        if (!Number.isNaN(value) && value >= 0) {
-          block.filesModified = value;
-        } else {
-          parseErrors.push(`Invalid FILES_MODIFIED value: "${filesMatch[1]}". Expected: non-negative integer`);
-        }
-        matched = true;
-      }
-
-      // TESTS_STATUS field
-      const testsMatch = trimmedLine.match(RALPH_TESTS_STATUS_PATTERN);
-      if (testsMatch) {
-        const value = testsMatch[1].toUpperCase();
-        if (['PASSING', 'FAILING', 'NOT_RUN'].includes(value)) {
-          block.testsStatus = value as RalphTestsStatus;
-        } else {
-          parseErrors.push(`Invalid TESTS_STATUS value: "${value}". Expected: PASSING, FAILING, or NOT_RUN`);
-        }
-        matched = true;
-      }
-
-      // WORK_TYPE field
-      const workMatch = trimmedLine.match(RALPH_WORK_TYPE_PATTERN);
-      if (workMatch) {
-        const value = workMatch[1].toUpperCase();
-        if (['IMPLEMENTATION', 'TESTING', 'DOCUMENTATION', 'REFACTORING'].includes(value)) {
-          block.workType = value as RalphWorkType;
-        } else {
-          parseErrors.push(
-            `Invalid WORK_TYPE value: "${value}". Expected: IMPLEMENTATION, TESTING, DOCUMENTATION, or REFACTORING`
-          );
-        }
-        matched = true;
-      }
-
-      // EXIT_SIGNAL field
-      const exitMatch = trimmedLine.match(RALPH_EXIT_SIGNAL_PATTERN);
-      if (exitMatch) {
-        block.exitSignal = exitMatch[1].toLowerCase() === 'true';
-        matched = true;
-      }
-
-      // RECOMMENDATION field
-      const recMatch = trimmedLine.match(RALPH_RECOMMENDATION_PATTERN);
-      if (recMatch) {
-        block.recommendation = recMatch[1].trim();
-        matched = true;
       }
 
       // Track unknown fields for debugging (only if looks like a field)
@@ -475,38 +472,9 @@ export class RalphStatusParser extends EventEmitter {
     const prevState = this._circuitBreaker.state;
 
     if (hasProgress) {
-      // Progress detected - reset counters, possibly close circuit
-      this._circuitBreaker.consecutiveNoProgress = 0;
-      this._circuitBreaker.consecutiveSameError = 0;
-      this._circuitBreaker.lastProgressIteration = this._cycleCount;
-
-      if (this._circuitBreaker.state === 'HALF_OPEN') {
-        this._circuitBreaker.state = 'CLOSED';
-        this._circuitBreaker.reason = 'Progress detected, circuit closed';
-        this._circuitBreaker.reasonCode = 'progress_detected';
-      }
+      this._handleProgressDetected();
     } else {
-      // No progress
-      this._circuitBreaker.consecutiveNoProgress++;
-
-      // State transitions based on consecutive no-progress
-      if (this._circuitBreaker.state === 'CLOSED') {
-        if (this._circuitBreaker.consecutiveNoProgress >= 3) {
-          this._circuitBreaker.state = 'OPEN';
-          this._circuitBreaker.reason = `No progress for ${this._circuitBreaker.consecutiveNoProgress} iterations`;
-          this._circuitBreaker.reasonCode = 'no_progress_open';
-        } else if (this._circuitBreaker.consecutiveNoProgress >= 2) {
-          this._circuitBreaker.state = 'HALF_OPEN';
-          this._circuitBreaker.reason = 'Warning: no progress detected';
-          this._circuitBreaker.reasonCode = 'no_progress_warning';
-        }
-      } else if (this._circuitBreaker.state === 'HALF_OPEN') {
-        if (this._circuitBreaker.consecutiveNoProgress >= 3) {
-          this._circuitBreaker.state = 'OPEN';
-          this._circuitBreaker.reason = `No progress for ${this._circuitBreaker.consecutiveNoProgress} iterations`;
-          this._circuitBreaker.reasonCode = 'no_progress_open';
-        }
-      }
+      this._handleNoProgress();
     }
 
     // Track tests failure
@@ -535,6 +503,40 @@ export class RalphStatusParser extends EventEmitter {
     }
   }
 
+  private _handleProgressDetected(): void {
+    this._circuitBreaker.consecutiveNoProgress = 0;
+    this._circuitBreaker.consecutiveSameError = 0;
+    this._circuitBreaker.lastProgressIteration = this._cycleCount;
+
+    if (this._circuitBreaker.state === 'HALF_OPEN') {
+      this._circuitBreaker.state = 'CLOSED';
+      this._circuitBreaker.reason = 'Progress detected, circuit closed';
+      this._circuitBreaker.reasonCode = 'progress_detected';
+    }
+  }
+
+  private _handleNoProgress(): void {
+    this._circuitBreaker.consecutiveNoProgress++;
+
+    if (this._circuitBreaker.state === 'CLOSED') {
+      if (this._circuitBreaker.consecutiveNoProgress >= 3) {
+        this._circuitBreaker.state = 'OPEN';
+        this._circuitBreaker.reason = `No progress for ${this._circuitBreaker.consecutiveNoProgress} iterations`;
+        this._circuitBreaker.reasonCode = 'no_progress_open';
+      } else if (this._circuitBreaker.consecutiveNoProgress >= 2) {
+        this._circuitBreaker.state = 'HALF_OPEN';
+        this._circuitBreaker.reason = 'Warning: no progress detected';
+        this._circuitBreaker.reasonCode = 'no_progress_warning';
+      }
+    } else if (this._circuitBreaker.state === 'HALF_OPEN') {
+      if (this._circuitBreaker.consecutiveNoProgress >= 3) {
+        this._circuitBreaker.state = 'OPEN';
+        this._circuitBreaker.reason = `No progress for ${this._circuitBreaker.consecutiveNoProgress} iterations`;
+        this._circuitBreaker.reasonCode = 'no_progress_open';
+      }
+    }
+  }
+
   /**
    * Check line for completion indicators (natural language patterns).
    * Used for dual-condition exit gate.

src/ralph-tracker.ts

@@ -100,6 +100,18 @@ const TODO_CLEANUP_INTERVAL_MS = INACTIVITY_TIMEOUT_MS;
  */
 const TODO_SIMILARITY_THRESHOLD = 0.85;
 
+/**
+ * Similarity threshold for short todo content (<30 chars).
+ * Higher threshold reduces false positive deduplication of short strings.
+ */
+const SIMILARITY_THRESHOLD_SHORT = 0.95;
+
+/**
+ * Similarity threshold for medium-length todo content (30-60 chars).
+ * Slightly relaxed compared to short strings.
+ */
+const SIMILARITY_THRESHOLD_MEDIUM = 0.9;
+
 /**
  * Debounce interval for event emissions (milliseconds).
  * Prevents UI jitter from rapid consecutive updates.
@@ -1299,6 +1311,24 @@ export class RalphTracker extends EventEmitter {
     this.detectTodoItems(trimmed);
   }
 
+  /**
+   * Mark all tracked todos as completed and emit todoUpdate if any changed.
+   * @returns true if any todo was updated
+   */
+  private completeAllTodos(): boolean {
+    let updated = false;
+    for (const todo of this._todos.values()) {
+      if (todo.status !== 'completed') {
+        todo.status = 'completed';
+        updated = true;
+      }
+    }
+    if (updated) {
+      this.emit('todoUpdate', this.todos);
+    }
+    return updated;
+  }
+
   /**
    * Detect "all tasks complete" messages.
    */
@@ -1318,16 +1348,7 @@ export class RalphTracker extends EventEmitter {
       return;
     }
 
-    let updated = false;
-    for (const todo of this._todos.values()) {
-      if (todo.status !== 'completed') {
-        todo.status = 'completed';
-        updated = true;
-      }
-    }
-    if (updated) {
-      this.emit('todoUpdate', this.todos);
-    }
+    this.completeAllTodos();
 
     if (this._loopState.completionPhrase) {
       this._loopState.active = false;
@@ -1425,16 +1446,7 @@ export class RalphTracker extends EventEmitter {
 
     if (bareCount > 1) return;
 
-    let updated = false;
-    for (const todo of this._todos.values()) {
-      if (todo.status !== 'completed') {
-        todo.status = 'completed';
-        updated = true;
-      }
-    }
-    if (updated) {
-      this.emit('todoUpdate', this.todos);
-    }
+    this.completeAllTodos();
 
     this._loopState.active = false;
     this._loopState.lastActivity = Date.now();
@@ -1480,16 +1492,7 @@ export class RalphTracker extends EventEmitter {
       if (canonicalCount >= 2 || this._loopState.active) {
         this._loopState.active = false;
         this._loopState.lastActivity = Date.now();
-        let updated = false;
-        for (const todo of this._todos.values()) {
-          if (todo.status !== 'completed') {
-            todo.status = 'completed';
-            updated = true;
-          }
-        }
-        if (updated) {
-          this.emit('todoUpdate', this.todos);
-        }
+        this.completeAllTodos();
         this.emit('completionDetected', matchedPhrase);
         this.emit('loopUpdate', this.loopState);
         return;
@@ -1497,16 +1500,7 @@ export class RalphTracker extends EventEmitter {
     }
 
     if (this._loopState.active || count >= 2) {
-      let updated = false;
-      for (const todo of this._todos.values()) {
-        if (todo.status !== 'completed') {
-          todo.status = 'completed';
-          updated = true;
-        }
-      }
-      if (updated) {
-        this.emit('todoUpdate', this.todos);
-      }
+      this.completeAllTodos();
 
       this._loopState.active = false;
       this._loopState.lastActivity = Date.now();
@@ -1532,41 +1526,39 @@ export class RalphTracker extends EventEmitter {
     const suggestedPhrase = `${phrase}_${uniqueSuffix}`;
 
     if (COMMON_COMPLETION_PHRASES.has(normalized)) {
-      console.warn(
-        `[RalphTracker] Warning: Completion phrase "${phrase}" is very common and may cause false positives. Consider using: "${suggestedPhrase}"`
-      );
-      this.emit('phraseValidationWarning', {
-        phrase,
-        reason: 'common',
-        suggestedPhrase,
-      });
+      this.emitValidationWarning(phrase, 'common', suggestedPhrase);
       return;
     }
 
     if (normalized.length < MIN_RECOMMENDED_PHRASE_LENGTH) {
-      console.warn(
-        `[RalphTracker] Warning: Completion phrase "${phrase}" is too short (${normalized.length} chars). Consider using: "${suggestedPhrase}"`
-      );
-      this.emit('phraseValidationWarning', {
-        phrase,
-        reason: 'short',
-        suggestedPhrase,
-      });
+      this.emitValidationWarning(phrase, 'short', suggestedPhrase);
       return;
     }
 
     if (/^\d+$/.test(normalized)) {
-      console.warn(
-        `[RalphTracker] Warning: Completion phrase "${phrase}" is numeric-only and may cause false positives. Consider using: "${suggestedPhrase}"`
-      );
-      this.emit('phraseValidationWarning', {
-        phrase,
-        reason: 'numeric',
-        suggestedPhrase,
-      });
+      this.emitValidationWarning(phrase, 'numeric', suggestedPhrase);
     }
   }
 
+  /**
+   * Emit a phrase validation warning with a console message and event.
+   */
+  private emitValidationWarning(phrase: string, reason: 'common' | 'short' | 'numeric', suggestedPhrase: string): void {
+    const descriptions: Record<'common' | 'short' | 'numeric', string> = {
+      common: 'is very common and may cause false positives',
+      short: `is too short (${phrase.toUpperCase().replace(/[\s_\-.]+/g, '').length} chars)`,
+      numeric: 'is numeric-only and may cause false positives',
+    };
+    console.warn(
+      `[RalphTracker] Warning: Completion phrase "${phrase}" ${descriptions[reason]}. Consider using: "${suggestedPhrase}"`
+    );
+    this.emit('phraseValidationWarning', {
+      phrase,
+      reason,
+      suggestedPhrase,
+    });
+  }
+
   /**
    * Activate the loop if not already active.
    */
@@ -1977,9 +1969,9 @@ export class RalphTracker extends EventEmitter {
 
     let threshold: number;
     if (normalized.length < 30) {
-      threshold = 0.95;
+      threshold = SIMILARITY_THRESHOLD_SHORT;
     } else if (normalized.length < 60) {
-      threshold = 0.9;
+      threshold = SIMILARITY_THRESHOLD_MEDIUM;
     } else {
       threshold = TODO_SIMILARITY_THRESHOLD;
     }

src/respawn-controller.ts

@@ -70,12 +70,13 @@ import {
   AI_PLAN_CHECK_TIMEOUT_MS,
   AI_PLAN_CHECK_COOLDOWN_MS,
 } from './config/ai-defaults.js';
-import type {
-  RespawnCycleMetrics,
-  RespawnAggregateMetrics,
-  RalphLoopHealthScore,
-  TimingHistory,
-  CycleOutcome,
+import {
+  getErrorMessage,
+  type RespawnCycleMetrics,
+  type RespawnAggregateMetrics,
+  type RalphLoopHealthScore,
+  type TimingHistory,
+  type CycleOutcome,
 } from './types.js';
 
 // ========== Constants ==========
@@ -551,6 +552,14 @@ export interface RespawnEvents {
   respawnBlocked: (data: { reason: string; details: string }) => void;
 }
 
+/**
+ * Convert milliseconds to a non-negative whole number of seconds for countdown display.
+ * Rounds up so that e.g. 1200 ms shows as 2 s (never under-reports remaining time).
+ */
+function formatRemainingSeconds(ms: number): number {
+  return Math.max(0, Math.ceil(ms / 1000));
+}
+
 /** Default configuration values */
 const DEFAULT_CONFIG: RespawnConfig = {
   idleTimeoutMs: 10000, // 10 seconds of no activity after prompt (legacy, still used as fallback)
@@ -839,27 +848,42 @@ export class RespawnController extends EventEmitter {
   private validateConfig(): void {
     const c = this.config;
 
-    // Ensure timeouts are positive
-    if (c.idleTimeoutMs <= 0) c.idleTimeoutMs = DEFAULT_CONFIG.idleTimeoutMs;
-    if (c.completionConfirmMs <= 0) c.completionConfirmMs = DEFAULT_CONFIG.completionConfirmMs;
-    if (c.noOutputTimeoutMs <= 0) c.noOutputTimeoutMs = DEFAULT_CONFIG.noOutputTimeoutMs;
-    if (c.autoAcceptDelayMs < 0) c.autoAcceptDelayMs = DEFAULT_CONFIG.autoAcceptDelayMs;
-    if (c.interStepDelayMs <= 0) c.interStepDelayMs = DEFAULT_CONFIG.interStepDelayMs;
+    /**
+     * Validate that a timeout value is positive (or non-negative when allowZero is true).
+     * Falls back to the DEFAULT_CONFIG value if invalid.
+     */
+    const validatePositiveTimeout = (field: keyof RespawnConfig, allowZero = false): void => {
+      const value = c[field] as number;
+      const invalid = allowZero ? value < 0 : value <= 0;
+      if (invalid) {
+        // eslint-disable-next-line @typescript-eslint/no-explicit-any
+        (c as any)[field] = DEFAULT_CONFIG[field];
+      }
+    };
+
+    const REQUIRED_TIMEOUT_FIELDS = [
+      'idleTimeoutMs',
+      'completionConfirmMs',
+      'noOutputTimeoutMs',
+      'interStepDelayMs',
+      'aiIdleCheckTimeoutMs',
+      'aiIdleCheckMaxContext',
+      'aiPlanCheckTimeoutMs',
+      'aiPlanCheckMaxContext',
+    ] as const;
+    for (const field of REQUIRED_TIMEOUT_FIELDS) {
+      validatePositiveTimeout(field);
+    }
+
+    const ALLOW_ZERO_FIELDS = ['autoAcceptDelayMs', 'aiIdleCheckCooldownMs', 'aiPlanCheckCooldownMs'] as const;
+    for (const field of ALLOW_ZERO_FIELDS) {
+      validatePositiveTimeout(field, true);
+    }
 
     // Ensure completion confirm doesn't exceed no-output timeout
     if (c.completionConfirmMs > c.noOutputTimeoutMs) {
       c.completionConfirmMs = c.noOutputTimeoutMs;
     }
-
-    // Ensure AI check timeouts are positive
-    if (c.aiIdleCheckTimeoutMs <= 0) c.aiIdleCheckTimeoutMs = DEFAULT_CONFIG.aiIdleCheckTimeoutMs;
-    if (c.aiIdleCheckCooldownMs < 0) c.aiIdleCheckCooldownMs = DEFAULT_CONFIG.aiIdleCheckCooldownMs;
-    if (c.aiIdleCheckMaxContext <= 0) c.aiIdleCheckMaxContext = DEFAULT_CONFIG.aiIdleCheckMaxContext;
-
-    // Ensure plan check timeouts are positive
-    if (c.aiPlanCheckTimeoutMs <= 0) c.aiPlanCheckTimeoutMs = DEFAULT_CONFIG.aiPlanCheckTimeoutMs;
-    if (c.aiPlanCheckCooldownMs < 0) c.aiPlanCheckCooldownMs = DEFAULT_CONFIG.aiPlanCheckCooldownMs;
-    if (c.aiPlanCheckMaxContext <= 0) c.aiPlanCheckMaxContext = DEFAULT_CONFIG.aiPlanCheckMaxContext;
   }
 
   /** Wire up AI checker events to controller events (removes existing listeners first to prevent duplicates) */
@@ -987,11 +1011,11 @@ export class RespawnController extends EventEmitter {
       waitingFor = 'AI verdict (IDLE or WORKING)';
     } else if (this._state === 'confirming_idle') {
       statusText = `Confirming idle (${confidence}% confidence)`;
-      waitingFor = `${Math.max(0, Math.ceil((this.config.completionConfirmMs - msSinceLastOutput) / 1000))}s more silence`;
+      waitingFor = `${formatRemainingSeconds(this.config.completionConfirmMs - msSinceLastOutput)}s more silence`;
     } else if (this._state === 'watching') {
       const aiState = this.aiChecker.getState();
       if (aiState.status === 'cooldown') {
-        const remaining = Math.ceil(this.aiChecker.getCooldownRemainingMs() / 1000);
+        const remaining = formatRemainingSeconds(this.aiChecker.getCooldownRemainingMs());
         statusText = `AI Check: WORKING (cooldown ${remaining}s)`;
         waitingFor = 'Cooldown to expire';
       } else if (completionMessageDetected) {
@@ -1364,98 +1388,13 @@ export class RespawnController extends EventEmitter {
       this.lastTokenChangeTime = now;
     }
 
-    // Detect completion message FIRST (Layer 1) - PRIMARY DETECTION
-    // Check this before working patterns because completion message indicates
-    // the work is done, even if working patterns are still in the rolling window
-    if (isCompletionMessage(data)) {
-      // Clear the rolling window - completion marks a transition point
-      this.clearWorkingPatternWindow();
-      this.workingDetected = false;
-      this.completionMessageTime = now;
-      this.cancelAutoAcceptTimer(); // Normal idle flow handles this
-      this.log(`Completion message detected: "${data.trim().substring(0, 50)}..."`);
+    // Layer 1: Completion message (PRIMARY) — checked before working patterns
+    if (this._detectCompletionMessage(data, now)) return;
 
-      // In watching state, start completion confirmation timer
-      if (this._state === 'watching') {
-        this.startCompletionConfirmTimer();
-        return;
-      }
+    // Layer 4: Working patterns
+    if (this._detectWorkingPattern(data, now)) return;
 
-      // In waiting states, also use confirmation timer (same detection logic)
-      // This ensures we wait for Claude to finish before proceeding
-      // Note: 'watching' is already handled above and returns early
-      switch (this._state) {
-        case 'waiting_update':
-          this.startStepConfirmTimer('update');
-          break;
-        case 'waiting_clear':
-          this.checkClearComplete(); // /clear is quick, no need to wait
-          break;
-        case 'waiting_init':
-          this.startStepConfirmTimer('init');
-          break;
-        case 'waiting_kickstart':
-          this.startStepConfirmTimer('kickstart');
-          break;
-        // Non-waiting states: completion message is ignored
-        case 'confirming_idle':
-        case 'ai_checking':
-        case 'sending_update':
-        case 'sending_clear':
-        case 'sending_init':
-        case 'monitoring_init':
-        case 'sending_kickstart':
-        case 'stopped':
-          // Completion message during these states is ignored
-          break;
-        default:
-          assertNever(this._state, `Unhandled RespawnState in completion detection: ${this._state}`);
-      }
-      return;
-    }
-
-    // Detect working patterns (Layer 4)
-    const isWorking = this.checkWorkingPattern(data);
-    if (isWorking) {
-      this.workingDetected = true;
-      this.promptDetected = false;
-      this.elicitationDetected = false; // Clear on new work cycle
-      this.resetHookState(); // Clear hook signals on new work
-      this.lastWorkingPatternTime = now;
-
-      // Cancel hook confirmation timer if running
-      this.cancelTrackedTimer('hook-confirm', 'working patterns detected');
-
-      // Cancel any pending completion confirmation
-      this.cancelCompletionConfirm();
-
-      // Cancel any pending step confirmation (Claude is still working)
-      this.cancelStepConfirm();
-
-      // If AI check is running, cancel it (Claude is working)
-      if (this._state === 'ai_checking') {
-        this.log('Working patterns detected during AI check, cancelling');
-        this.aiChecker.cancel();
-        this.setState('watching');
-      }
-
-      // Cancel plan check if running (Claude started working)
-      if (this.planChecker.status === 'checking') {
-        this.log('Working patterns detected during plan check, cancelling');
-        this.planChecker.cancel();
-      }
-
-      // If we're monitoring init and work started, go to watching (no kickstart needed)
-      if (this._state === 'monitoring_init') {
-        this.log('/init triggered work, skipping kickstart');
-        this.emit('stepCompleted', 'init');
-        this.completeCycle();
-      }
-      return;
-    }
-
-    // In confirming_idle or ai_checking state, substantial output cancels the flow.
-    // This prevents false triggers when Claude pauses briefly mid-work.
+    // Substantial output during confirming_idle/ai_checking cancels the flow
     if (this._state === 'confirming_idle' || this._state === 'ai_checking') {
       // Strip ANSI escape codes to check if there's real content
       ANSI_ESCAPE_PATTERN_SIMPLE.lastIndex = 0;
@@ -1476,43 +1415,137 @@ export class RespawnController extends EventEmitter {
       }
     }
 
-    // Legacy fallback: detect prompt characters (still useful for waiting_* states)
-    const hasPrompt = PROMPT_PATTERNS.some((pattern) => data.includes(pattern));
-    if (hasPrompt) {
-      this.promptDetected = true;
-      this.workingDetected = false;
+    // Legacy fallback: prompt detection
+    this._detectPrompt(data);
+  }
 
-      // Handle legacy detection in waiting states - also use confirmation timers
-      switch (this._state) {
-        case 'waiting_update':
-          this.startStepConfirmTimer('update');
-          break;
-        case 'waiting_clear':
-          this.checkClearComplete(); // /clear is quick, no need to wait
-          break;
-        case 'waiting_init':
-          this.startStepConfirmTimer('init');
-          break;
-        case 'monitoring_init':
-          this.checkMonitoringInitIdle();
-          break;
-        case 'waiting_kickstart':
-          this.startStepConfirmTimer('kickstart');
-          break;
-        // Non-waiting states: prompt detection is informational only
-        case 'watching':
-        case 'confirming_idle':
-        case 'ai_checking':
-        case 'sending_update':
-        case 'sending_clear':
-        case 'sending_init':
-        case 'sending_kickstart':
-        case 'stopped':
-          // Prompt detection during these states doesn't trigger action
-          break;
-        default:
-          assertNever(this._state, `Unhandled RespawnState in prompt detection: ${this._state}`);
-      }
+  private _detectCompletionMessage(data: string, now: number): boolean {
+    if (!isCompletionMessage(data)) return false;
+
+    // Clear the rolling window - completion marks a transition point
+    this.clearWorkingPatternWindow();
+    this.workingDetected = false;
+    this.completionMessageTime = now;
+    this.cancelAutoAcceptTimer(); // Normal idle flow handles this
+    this.log(`Completion message detected: "${data.trim().substring(0, 50)}..."`);
+
+    // In watching state, start completion confirmation timer
+    if (this._state === 'watching') {
+      this.startCompletionConfirmTimer();
+      return true;
+    }
+
+    // In waiting states, also use confirmation timer (same detection logic)
+    // This ensures we wait for Claude to finish before proceeding
+    // Note: 'watching' is already handled above and returns early
+    switch (this._state) {
+      case 'waiting_update':
+        this.startStepConfirmTimer('update');
+        break;
+      case 'waiting_clear':
+        this.checkClearComplete(); // /clear is quick, no need to wait
+        break;
+      case 'waiting_init':
+        this.startStepConfirmTimer('init');
+        break;
+      case 'waiting_kickstart':
+        this.startStepConfirmTimer('kickstart');
+        break;
+      // Non-waiting states: completion message is ignored
+      case 'confirming_idle':
+      case 'ai_checking':
+      case 'sending_update':
+      case 'sending_clear':
+      case 'sending_init':
+      case 'monitoring_init':
+      case 'sending_kickstart':
+      case 'stopped':
+        // Completion message during these states is ignored
+        break;
+      default:
+        assertNever(this._state, `Unhandled RespawnState in completion detection: ${this._state}`);
+    }
+    return true;
+  }
+
+  private _detectWorkingPattern(data: string, now: number): boolean {
+    const isWorking = this.checkWorkingPattern(data);
+    if (!isWorking) return false;
+
+    this.workingDetected = true;
+    this.promptDetected = false;
+    this.elicitationDetected = false; // Clear on new work cycle
+    this.resetHookState(); // Clear hook signals on new work
+    this.lastWorkingPatternTime = now;
+
+    // Cancel hook confirmation timer if running
+    this.cancelTrackedTimer('hook-confirm', 'working patterns detected');
+
+    // Cancel any pending completion confirmation
+    this.cancelCompletionConfirm();
+
+    // Cancel any pending step confirmation (Claude is still working)
+    this.cancelStepConfirm();
+
+    // If AI check is running, cancel it (Claude is working)
+    if (this._state === 'ai_checking') {
+      this.log('Working patterns detected during AI check, cancelling');
+      this.aiChecker.cancel();
+      this.setState('watching');
+    }
+
+    // Cancel plan check if running (Claude started working)
+    if (this.planChecker.status === 'checking') {
+      this.log('Working patterns detected during plan check, cancelling');
+      this.planChecker.cancel();
+    }
+
+    // If we're monitoring init and work started, go to watching (no kickstart needed)
+    if (this._state === 'monitoring_init') {
+      this.log('/init triggered work, skipping kickstart');
+      this.emit('stepCompleted', 'init');
+      this.completeCycle();
+    }
+    return true;
+  }
+
+  private _detectPrompt(data: string): void {
+    const hasPrompt = PROMPT_PATTERNS.some((pattern) => data.includes(pattern));
+    if (!hasPrompt) return;
+
+    this.promptDetected = true;
+    this.workingDetected = false;
+
+    // Handle legacy detection in waiting states - also use confirmation timers
+    switch (this._state) {
+      case 'waiting_update':
+        this.startStepConfirmTimer('update');
+        break;
+      case 'waiting_clear':
+        this.checkClearComplete(); // /clear is quick, no need to wait
+        break;
+      case 'waiting_init':
+        this.startStepConfirmTimer('init');
+        break;
+      case 'monitoring_init':
+        this.checkMonitoringInitIdle();
+        break;
+      case 'waiting_kickstart':
+        this.startStepConfirmTimer('kickstart');
+        break;
+      // Non-waiting states: prompt detection is informational only
+      case 'watching':
+      case 'confirming_idle':
+      case 'ai_checking':
+      case 'sending_update':
+      case 'sending_clear':
+      case 'sending_init':
+      case 'sending_kickstart':
+      case 'stopped':
+        // Prompt detection during these states doesn't trigger action
+        break;
+      default:
+        assertNever(this._state, `Unhandled RespawnState in prompt detection: ${this._state}`);
     }
   }
 
@@ -1798,24 +1831,28 @@ export class RespawnController extends EventEmitter {
       case 'sending_init':
       case 'sending_kickstart':
         // For sending states, retry the send
-        this.log('Recovery: returning to watching state');
-        this.setState('watching');
-        this.startNoOutputTimer();
-        this.startPreFilterTimer();
-        if (this.config.autoAcceptPrompts) {
-          this.startAutoAcceptTimer();
-        }
+        this.recoveryResetToWatching('returning to watching state');
         break;
 
       default:
         // Fallback: reset to watching
-        this.log('Recovery: fallback to watching state');
-        this.setState('watching');
-        this.startNoOutputTimer();
-        this.startPreFilterTimer();
-        if (this.config.autoAcceptPrompts) {
-          this.startAutoAcceptTimer();
-        }
+        this.recoveryResetToWatching('fallback to watching state');
+    }
+  }
+
+  /**
+   * Reset the controller to watching state during stuck-state recovery.
+   * Sets state to watching and restarts all detection timers.
+   *
+   * @param reason - Human-readable reason for the reset (logged)
+   */
+  private recoveryResetToWatching(reason: string): void {
+    this.log(`Recovery: ${reason}`);
+    this.setState('watching');
+    this.startNoOutputTimer();
+    this.startPreFilterTimer();
+    if (this.config.autoAcceptPrompts) {
+      this.startAutoAcceptTimer();
     }
   }
 
@@ -2051,7 +2088,7 @@ export class RespawnController extends EventEmitter {
     // If on cooldown, don't start check - wait for cooldown to expire
     if (this.aiChecker.isOnCooldown()) {
       this.log(
-        `AI check on cooldown (${Math.ceil(this.aiChecker.getCooldownRemainingMs() / 1000)}s remaining), waiting...`
+        `AI check on cooldown (${formatRemainingSeconds(this.aiChecker.getCooldownRemainingMs())}s remaining), waiting...`
       );
       return;
     }
@@ -2136,7 +2173,7 @@ export class RespawnController extends EventEmitter {
         }
         if (this._state === 'stopped') return; // Guard against stopped state
         if (this._state === 'ai_checking') {
-          const errorMsg = err instanceof Error ? err.message : String(err);
+          const errorMsg = getErrorMessage(err);
           this.logAction('ai-check', `Failed: ${errorMsg.substring(0, 50)}`);
           this.emit('aiCheckFailed', errorMsg);
           this.setState('watching');
@@ -2198,36 +2235,15 @@ export class RespawnController extends EventEmitter {
    * @fires planCheckStarted
    */
   private tryAutoAccept(): void {
-    // Only auto-accept in watching state (not during a respawn cycle)
-    if (this._state !== 'watching') return;
+    if (!this.canAutoAccept()) return;
 
-    // Don't auto-accept if a completion message was detected (normal idle handles it)
-    if (this.completionMessageTime !== null) return;
-
-    // Don't auto-accept if disabled
-    if (!this.config.autoAcceptPrompts) return;
-
-    // Don't auto-accept if we haven't received any output yet (prevents spurious Enter on fresh start)
-    if (!this.hasReceivedOutput) return;
-
-    // Don't auto-accept if an elicitation dialog (AskUserQuestion) was detected
-    if (this.elicitationDetected) {
-      this.log('Skipping auto-accept: elicitation dialog detected (AskUserQuestion)');
-      return;
-    }
-
-    // Stage 1: Pre-filter — check if buffer looks like plan mode
     const buffer = this.terminalBuffer.value;
-    if (!this.isPlanModePreFilterMatch(buffer)) {
-      this.log('Skipping auto-accept: pre-filter did not match plan mode patterns');
-      return;
-    }
 
     // Stage 2: AI confirmation (if enabled and available)
     if (this.config.aiPlanCheckEnabled && this.planChecker.status !== 'disabled') {
       if (this.planChecker.isOnCooldown()) {
         this.log(
-          `Skipping auto-accept: plan checker on cooldown (${Math.ceil(this.planChecker.getCooldownRemainingMs() / 1000)}s remaining)`
+          `Skipping auto-accept: plan checker on cooldown (${formatRemainingSeconds(this.planChecker.getCooldownRemainingMs())}s remaining)`
         );
         return;
       }
@@ -2244,6 +2260,40 @@ export class RespawnController extends EventEmitter {
     this.sendAutoAcceptEnter();
   }
 
+  /**
+   * Check whether all preconditions for auto-accept are met.
+   * Validates state, config, and pre-filter conditions before attempting auto-accept.
+   *
+   * @returns True if auto-accept should proceed to the AI confirmation stage
+   */
+  private canAutoAccept(): boolean {
+    // Only auto-accept in watching state (not during a respawn cycle)
+    if (this._state !== 'watching') return false;
+
+    // Don't auto-accept if a completion message was detected (normal idle handles it)
+    if (this.completionMessageTime !== null) return false;
+
+    // Don't auto-accept if disabled
+    if (!this.config.autoAcceptPrompts) return false;
+
+    // Don't auto-accept if we haven't received any output yet (prevents spurious Enter on fresh start)
+    if (!this.hasReceivedOutput) return false;
+
+    // Don't auto-accept if an elicitation dialog (AskUserQuestion) was detected
+    if (this.elicitationDetected) {
+      this.log('Skipping auto-accept: elicitation dialog detected (AskUserQuestion)');
+      return false;
+    }
+
+    // Stage 1: Pre-filter — check if buffer looks like plan mode
+    if (!this.isPlanModePreFilterMatch(this.terminalBuffer.value)) {
+      this.log('Skipping auto-accept: pre-filter did not match plan mode patterns');
+      return false;
+    }
+
+    return true;
+  }
+
   /**
    * Check if the terminal buffer matches plan mode pre-filter patterns.
    * Only checks the last 2000 chars (plan mode UI appears at the bottom).
@@ -2322,7 +2372,7 @@ export class RespawnController extends EventEmitter {
         }
       })
       .catch((err) => {
-        const errorMsg = err instanceof Error ? err.message : String(err);
+        const errorMsg = getErrorMessage(err);
         this.emit('planCheckFailed', errorMsg);
         this.logAction('plan-check', `Failed: ${errorMsg.substring(0, 50)}`);
       });

src/session-auto-ops.ts

@@ -27,6 +27,57 @@ const COMPACT_COOLDOWN_MS = 10000;
 /** Cooldown after clear completes before re-enabling (5 seconds) */
 const CLEAR_COOLDOWN_MS = 5000;
 
+/**
+ * Executes an action when the session becomes idle, retrying if currently working.
+ *
+ * @param action - The async action to execute once idle
+ * @param isActive - Returns whether this operation is still active (not cancelled)
+ * @param isWorking - Returns whether the session is currently working
+ * @param isStopped - Returns whether the session has been stopped
+ * @param retryMs - Delay between retry attempts when working
+ * @param cooldownMs - Delay after action completes before calling onCooldownDone
+ * @param setTimer - Stores the timer reference for cleanup
+ * @param onCooldownDone - Called after cooldown to reset state
+ */
+async function executeWhenIdle(
+  action: () => Promise<void>,
+  isActive: () => boolean,
+  isWorking: () => boolean,
+  isStopped: () => boolean,
+  retryMs: number,
+  cooldownMs: number,
+  setTimer: (timer: NodeJS.Timeout | null) => void,
+  onCooldownDone: () => void
+): Promise<void> {
+  if (isStopped()) return;
+  if (!isActive()) return;
+
+  if (!isWorking()) {
+    if (isStopped()) return;
+
+    await action();
+
+    if (!isStopped()) {
+      setTimer(
+        setTimeout(() => {
+          if (isStopped()) return;
+          setTimer(null);
+          onCooldownDone();
+        }, cooldownMs)
+      );
+    }
+  } else {
+    if (!isStopped()) {
+      setTimer(
+        setTimeout(
+          () => executeWhenIdle(action, isActive, isWorking, isStopped, retryMs, cooldownMs, setTimer, onCooldownDone),
+          retryMs
+        )
+      );
+    }
+  }
+}
+
 /** Minimum valid threshold for auto-clear/compact (1000 tokens) */
 const MIN_AUTO_THRESHOLD = 1000;
 
@@ -181,37 +232,35 @@ export class SessionAutoOps extends EventEmitter {
         `[SessionAutoOps] Auto-compact triggered: ${totalTokens} tokens >= ${this._autoCompactThreshold} threshold`
       );
 
-      const checkAndCompact = async () => {
-        if (this.callbacks.isStopped()) return;
-        if (!this._isCompacting) return;
-
-        if (!this.callbacks.isWorking()) {
-          if (this.callbacks.isStopped()) return;
-
-          const compactCmd = this._autoCompactPrompt ? `/compact ${this._autoCompactPrompt}\r` : '/compact\r';
-          await this.callbacks.writeCommand(compactCmd);
-          this.emit('autoCompact', {
-            tokens: totalTokens,
-            threshold: this._autoCompactThreshold,
-            prompt: this._autoCompactPrompt || undefined,
-          });
-
-          if (!this.callbacks.isStopped()) {
-            this._autoCompactTimer = setTimeout(() => {
-              if (this.callbacks.isStopped()) return;
-              this._autoCompactTimer = null;
-              this._isCompacting = false;
-            }, COMPACT_COOLDOWN_MS);
-          }
-        } else {
-          if (!this.callbacks.isStopped()) {
-            this._autoCompactTimer = setTimeout(checkAndCompact, AUTO_RETRY_DELAY_MS);
-          }
-        }
+      const action = async () => {
+        const compactCmd = this._autoCompactPrompt ? `/compact ${this._autoCompactPrompt}\r` : '/compact\r';
+        await this.callbacks.writeCommand(compactCmd);
+        this.emit('autoCompact', {
+          tokens: totalTokens,
+          threshold: this._autoCompactThreshold,
+          prompt: this._autoCompactPrompt || undefined,
+        });
       };
 
       if (!this.callbacks.isStopped()) {
-        this._autoCompactTimer = setTimeout(checkAndCompact, AUTO_INITIAL_DELAY_MS);
+        this._autoCompactTimer = setTimeout(
+          () =>
+            executeWhenIdle(
+              action,
+              () => this._isCompacting,
+              () => this.callbacks.isWorking(),
+              () => this.callbacks.isStopped(),
+              AUTO_RETRY_DELAY_MS,
+              COMPACT_COOLDOWN_MS,
+              (timer) => {
+                this._autoCompactTimer = timer;
+              },
+              () => {
+                this._isCompacting = false;
+              }
+            ),
+          AUTO_INITIAL_DELAY_MS
+        );
       }
     }
   }
@@ -231,32 +280,30 @@ export class SessionAutoOps extends EventEmitter {
         `[SessionAutoOps] Auto-clear triggered: ${totalTokens} tokens >= ${this._autoClearThreshold} threshold`
       );
 
-      const checkAndClear = async () => {
-        if (this.callbacks.isStopped()) return;
-        if (!this._isClearing) return;
-
-        if (!this.callbacks.isWorking()) {
-          if (this.callbacks.isStopped()) return;
-
-          await this.callbacks.writeCommand('/clear\r');
-          this.emit('autoClear', { tokens: totalTokens, threshold: this._autoClearThreshold });
-
-          if (!this.callbacks.isStopped()) {
-            this._autoClearTimer = setTimeout(() => {
-              if (this.callbacks.isStopped()) return;
-              this._autoClearTimer = null;
-              this._isClearing = false;
-            }, CLEAR_COOLDOWN_MS);
-          }
-        } else {
-          if (!this.callbacks.isStopped()) {
-            this._autoClearTimer = setTimeout(checkAndClear, AUTO_RETRY_DELAY_MS);
-          }
-        }
+      const action = async () => {
+        await this.callbacks.writeCommand('/clear\r');
+        this.emit('autoClear', { tokens: totalTokens, threshold: this._autoClearThreshold });
       };
 
       if (!this.callbacks.isStopped()) {
-        this._autoClearTimer = setTimeout(checkAndClear, AUTO_INITIAL_DELAY_MS);
+        this._autoClearTimer = setTimeout(
+          () =>
+            executeWhenIdle(
+              action,
+              () => this._isClearing,
+              () => this.callbacks.isWorking(),
+              () => this.callbacks.isStopped(),
+              AUTO_RETRY_DELAY_MS,
+              CLEAR_COOLDOWN_MS,
+              (timer) => {
+                this._autoClearTimer = timer;
+              },
+              () => {
+                this._isClearing = false;
+              }
+            ),
+          AUTO_INITIAL_DELAY_MS
+        );
       }
     }
   }

src/session.ts

@@ -40,6 +40,7 @@ import {
   ActiveBashTool,
   NiceConfig,
   DEFAULT_NICE_CONFIG,
+  getErrorMessage,
   type ClaudeMode,
   type SessionMode,
   type OpenCodeConfig,
@@ -871,18 +872,77 @@ export class Session extends EventEmitter {
    * session.write('help me with this code\r');
    * ```
    */
+  private async _setupOrAttachMuxSession(options: {
+    respawnPaneOptions: import('./mux-interface.js').RespawnPaneOptions;
+    createSessionOptions: import('./mux-interface.js').CreateSessionOptions;
+    spawnErrLabel: string;
+  }): Promise<{ isRestored: boolean }> {
+    const mux = this._mux!;
+
+    // Verify stale mux session — tmux may have been destroyed (e.g., killed externally)
+    if (this._muxSession && !mux.muxSessionExists(this._muxSession.muxName)) {
+      console.log('[Session] Stale mux session detected (tmux gone):', this._muxSession.muxName);
+      this._muxSession = null;
+    }
+
+    // Check if session exists but pane is dead (remain-on-exit keeps it alive)
+    // Respawn the pane instead of creating a whole new session — preserves tmux scrollback
+    let needsNewSession = false;
+    if (this._muxSession && mux.isPaneDead(this._muxSession.muxName)) {
+      console.log('[Session] Dead pane detected, respawning:', this._muxSession.muxName);
+      const newPid = await mux.respawnPane(options.respawnPaneOptions);
+      if (!newPid) {
+        console.error('[Session] Failed to respawn pane, will create new session');
+        needsNewSession = true;
+      } else {
+        // Wait a moment for the respawned process to fully start
+        await new Promise((resolve) => setTimeout(resolve, MUX_STARTUP_DELAY_MS));
+      }
+    }
+
+    // Check if we already have a mux session (restored session)
+    const isRestored = this._muxSession !== null && !needsNewSession;
+    if (isRestored) {
+      console.log('[Session] Attaching to existing mux session:', this._muxSession!.muxName);
+    } else {
+      // Create a new mux session
+      this._muxSession = await mux.createSession(options.createSessionOptions);
+      console.log('[Session] Created mux session:', this._muxSession.muxName);
+      // No extra sleep — createSession() already waits for tmux readiness
+    }
+
+    // Attach to the mux session via PTY
+    try {
+      this.ptyProcess = pty.spawn(mux.getAttachCommand(), mux.getAttachArgs(this._muxSession!.muxName), {
+        name: 'xterm-256color',
+        cols: 120,
+        rows: 40,
+        cwd: this.workingDir,
+        env: buildMuxAttachEnv(),
+      });
+    } catch (spawnErr) {
+      console.error(`[Session] Failed to spawn PTY for ${options.spawnErrLabel}:`, spawnErr);
+      this.emit('error', `Failed to attach to mux session: ${spawnErr}`);
+      throw spawnErr;
+    }
+
+    return { isRestored };
+  }
+
+  private _handleTerminalOutput(data: string): void {
+    // BufferAccumulator handles auto-trimming when max size exceeded
+    this._terminalBuffer.append(data);
+    this._lastActivityAt = Date.now();
+    this.emit('terminal', data);
+    this.emit('output', data);
+  }
+
   async startInteractive(): Promise<void> {
     if (this.ptyProcess) {
       throw new Error('Session already has a running process');
     }
 
-    this._status = 'busy';
-    this._terminalBuffer.clear();
-    this._textOutput.clear();
-    this._errorBuffer = '';
-    this._messages = [];
-    this._lineBuffer = '';
-    this._lastActivityAt = Date.now();
+    this._resetBuffers();
 
     const modeLabel = this.mode === 'opencode' ? 'OpenCode' : 'Claude';
     console.log(
@@ -892,18 +952,8 @@ export class Session extends EventEmitter {
     // If mux wrapping is enabled, create or attach to a mux session
     if (this._useMux && this._mux) {
       try {
-        // Verify stale mux session — tmux may have been destroyed (e.g., killed externally)
-        if (this._muxSession && !this._mux.muxSessionExists(this._muxSession.muxName)) {
-          console.log('[Session] Stale mux session detected (tmux gone):', this._muxSession.muxName);
-          this._muxSession = null;
-        }
-
-        // Check if session exists but pane is dead (remain-on-exit keeps it alive)
-        // Respawn the pane instead of creating a whole new session — preserves tmux scrollback
-        let needsNewSession = false;
-        if (this._muxSession && this._mux.isPaneDead(this._muxSession.muxName)) {
-          console.log('[Session] Dead pane detected, respawning:', this._muxSession.muxName);
-          const newPid = await this._mux.respawnPane({
+        const { isRestored } = await this._setupOrAttachMuxSession({
+          respawnPaneOptions: {
             sessionId: this.id,
             workingDir: this.workingDir,
             mode: this.mode,
@@ -913,23 +963,8 @@ export class Session extends EventEmitter {
             allowedTools: this._allowedTools,
             openCodeConfig: this._openCodeConfig,
             resumeSessionId: this._resumeSessionId,
-          });
-          if (!newPid) {
-            console.error('[Session] Failed to respawn pane, will create new session');
-            needsNewSession = true;
-          } else {
-            // Wait a moment for the respawned process to fully start
-            await new Promise((resolve) => setTimeout(resolve, MUX_STARTUP_DELAY_MS));
-          }
-        }
-
-        // Check if we already have a mux session (restored session)
-        const isRestoredSession = this._muxSession !== null && !needsNewSession;
-        if (isRestoredSession) {
-          console.log('[Session] Attaching to existing mux session:', this._muxSession!.muxName);
-        } else {
-          // Create a new mux session
-          this._muxSession = await this._mux.createSession({
+          },
+          createSessionOptions: {
             sessionId: this.id,
             workingDir: this.workingDir,
             mode: this.mode,
@@ -940,36 +975,16 @@ export class Session extends EventEmitter {
             allowedTools: this._allowedTools,
             openCodeConfig: this._openCodeConfig,
             resumeSessionId: this._resumeSessionId,
-          });
-          console.log('[Session] Created mux session:', this._muxSession.muxName);
-          // No extra sleep — createSession() already waits for tmux readiness
-        }
+          },
+          spawnErrLabel: 'mux attachment',
+        });
 
-        // Attach to the mux session via PTY
-        try {
-          this.ptyProcess = pty.spawn(
-            this._mux.getAttachCommand(),
-            this._mux.getAttachArgs(this._muxSession!.muxName),
-            {
-              name: 'xterm-256color',
-              cols: 120,
-              rows: 40,
-              cwd: this.workingDir,
-              env: buildMuxAttachEnv(),
-            }
-          );
-
-          // Set claudeSessionId — when resuming, the Claude conversation ID is the resumed one.
-          this._claudeSessionId = this._resumeSessionId || this.id;
-        } catch (spawnErr) {
-          console.error('[Session] Failed to spawn PTY for mux attachment:', spawnErr);
-          this.emit('error', `Failed to attach to mux session: ${spawnErr}`);
-          throw spawnErr;
-        }
+        // Set claudeSessionId — when resuming, the Claude conversation ID is the resumed one.
+        this._claudeSessionId = this._resumeSessionId || this.id;
 
         // For NEW mux sessions: wait for readiness then clean buffer
         // For RESTORED mux sessions: don't do anything - client will fetch buffer on tab switch
-        if (!isRestoredSession) {
+        if (!isRestored) {
           if (this.mode === 'opencode') {
             // OpenCode uses Bubble Tea TUI — no ❯ prompt to detect.
             // Wait for TUI to stabilize (output stops changing), then mark ready.
@@ -1056,12 +1071,7 @@ export class Session extends EventEmitter {
       const data = rawData.replace(FOCUS_ESCAPE_FILTER, '').replace(CTRL_L_PATTERN, ''); // Remove Ctrl+L
       if (!data) return; // Skip if only filtered sequences
 
-      // BufferAccumulator handles auto-trimming when max size exceeded
-      this._terminalBuffer.append(data);
-      this._lastActivityAt = Date.now();
-
-      this.emit('terminal', data);
-      this.emit('output', data);
+      this._handleTerminalOutput(data);
 
       // === Idle/working detection runs on every chunk (latency-sensitive) ===
       // Detect if Claude is working or at prompt
@@ -1257,13 +1267,7 @@ export class Session extends EventEmitter {
       throw new Error('Session already has a running process');
     }
 
-    this._status = 'busy';
-    this._terminalBuffer.clear();
-    this._textOutput.clear();
-    this._errorBuffer = '';
-    this._messages = [];
-    this._lineBuffer = '';
-    this._lastActivityAt = Date.now();
+    this._resetBuffers();
 
     // Use user's default shell or bash
     const shell = process.env.SHELL || '/bin/bash';
@@ -1275,69 +1279,26 @@ export class Session extends EventEmitter {
     // If mux wrapping is enabled, create or attach to a mux session
     if (this._useMux && this._mux) {
       try {
-        // Verify stale mux session — tmux may have been destroyed externally
-        if (this._muxSession && !this._mux.muxSessionExists(this._muxSession.muxName)) {
-          console.log('[Session] Stale mux session detected (tmux gone):', this._muxSession.muxName);
-          this._muxSession = null;
-        }
-
-        // Check if session exists but pane is dead (remain-on-exit keeps it alive)
-        let needsNewSession = false;
-        if (this._muxSession && this._mux.isPaneDead(this._muxSession.muxName)) {
-          console.log('[Session] Dead pane detected, respawning:', this._muxSession.muxName);
-          const newPid = await this._mux.respawnPane({
+        const { isRestored } = await this._setupOrAttachMuxSession({
+          respawnPaneOptions: {
             sessionId: this.id,
             workingDir: this.workingDir,
             mode: 'shell',
             niceConfig: this._niceConfig,
-          });
-          if (!newPid) {
-            console.error('[Session] Failed to respawn pane, will create new session');
-            needsNewSession = true;
-          } else {
-            await new Promise((resolve) => setTimeout(resolve, MUX_STARTUP_DELAY_MS));
-          }
-        }
-
-        // Check if we already have a mux session (restored session)
-        const isRestoredSession = this._muxSession !== null && !needsNewSession;
-        if (isRestoredSession) {
-          console.log('[Session] Attaching to existing mux session:', this._muxSession!.muxName);
-        } else {
-          // Create a new mux session
-          this._muxSession = await this._mux.createSession({
+          },
+          createSessionOptions: {
             sessionId: this.id,
             workingDir: this.workingDir,
             mode: 'shell',
             name: this._name,
             niceConfig: this._niceConfig,
-          });
-          console.log('[Session] Created mux session:', this._muxSession.muxName);
-          // No extra sleep — createSession() already waits for tmux readiness
-        }
-
-        // Attach to the mux session via PTY
-        try {
-          this.ptyProcess = pty.spawn(
-            this._mux.getAttachCommand(),
-            this._mux.getAttachArgs(this._muxSession!.muxName),
-            {
-              name: 'xterm-256color',
-              cols: 120,
-              rows: 40,
-              cwd: this.workingDir,
-              env: buildMuxAttachEnv(),
-            }
-          );
-        } catch (spawnErr) {
-          console.error('[Session] Failed to spawn PTY for shell mux attachment:', spawnErr);
-          this.emit('error', `Failed to attach to mux session: ${spawnErr}`);
-          throw spawnErr;
-        }
+          },
+          spawnErrLabel: 'shell mux attachment',
+        });
 
         // For NEW sessions: clear by sending 'clear' command to the shell
         // For RESTORED sessions: don't clear - we want to see the existing output
-        if (!isRestoredSession) {
+        if (!isRestored) {
           setTimeout(() => {
             if (this.ptyProcess) {
               this._terminalBuffer.clear();
@@ -1378,12 +1339,7 @@ export class Session extends EventEmitter {
       const data = rawData.replace(FOCUS_ESCAPE_FILTER, '');
       if (!data) return; // Skip if only focus sequences
 
-      // BufferAccumulator handles auto-trimming when max size exceeded
-      this._terminalBuffer.append(data);
-      this._lastActivityAt = Date.now();
-
-      this.emit('terminal', data);
-      this.emit('output', data);
+      this._handleTerminalOutput(data);
     });
 
     this.ptyProcess.onExit(({ exitCode }) => {
@@ -1448,13 +1404,7 @@ export class Session extends EventEmitter {
         return;
       }
 
-      this._status = 'busy';
-      this._terminalBuffer.clear();
-      this._textOutput.clear();
-      this._errorBuffer = '';
-      this._messages = [];
-      this._lineBuffer = '';
-      this._lastActivityAt = Date.now();
+      this._resetBuffers();
       this._promptResolved = false; // Reset race condition guard
 
       this.resolvePromise = resolve;
@@ -1497,12 +1447,7 @@ export class Session extends EventEmitter {
           const data = rawData.replace(FOCUS_ESCAPE_FILTER, '');
           if (!data) return; // Skip if only focus sequences
 
-          // BufferAccumulator handles auto-trimming when max size exceeded
-          this._terminalBuffer.append(data);
-          this._lastActivityAt = Date.now();
-
-          this.emit('terminal', data);
-          this.emit('output', data);
+          this._handleTerminalOutput(data);
 
           // Also try to parse JSON lines for structured data
           this.processOutput(data);
@@ -1534,9 +1479,11 @@ export class Session extends EventEmitter {
             this._status = 'idle';
             const cost = resultMsg.total_cost_usd || 0;
             this._totalCost += cost;
-            this.emit('completion', resultMsg.result || '', cost);
+            // Claude CLI stream-json may return empty result field — fall back to accumulated text output
+            const result = resultMsg.result || this._textOutput.value || '';
+            this.emit('completion', result, cost);
             if (resolve) {
-              resolve({ result: resultMsg.result || '', cost });
+              resolve({ result, cost });
             }
           } else if (exitCode !== 0 || (resultMsg && resultMsg.is_error)) {
             this._status = 'error';
@@ -1565,6 +1512,117 @@ export class Session extends EventEmitter {
     });
   }
 
+  private _resetBuffers(): void {
+    this._status = 'busy';
+    this._terminalBuffer.clear();
+    this._textOutput.clear();
+    this._errorBuffer = '';
+    this._messages = [];
+    this._lineBuffer = '';
+    this._lastActivityAt = Date.now();
+  }
+
+  private _clearAllTimers(): void {
+    // Clear activity timeout to prevent memory leak
+    if (this.activityTimeout) {
+      clearTimeout(this.activityTimeout);
+      this.activityTimeout = null;
+    }
+
+    // Clear line buffer flush timer
+    if (this._lineBufferFlushTimer) {
+      clearTimeout(this._lineBufferFlushTimer);
+      this._lineBufferFlushTimer = null;
+    }
+
+    // Destroy auto-compact/auto-clear automation (clears its timers)
+    this._autoOps.destroy();
+
+    // Clear prompt check timers
+    if (this._promptCheckInterval) {
+      clearInterval(this._promptCheckInterval);
+      this._promptCheckInterval = null;
+    }
+    if (this._promptCheckTimeout) {
+      clearTimeout(this._promptCheckTimeout);
+      this._promptCheckTimeout = null;
+    }
+
+    // Clear shell idle timer
+    if (this._shellIdleTimer) {
+      clearTimeout(this._shellIdleTimer);
+      this._shellIdleTimer = null;
+    }
+
+    // Clear expensive processing timer
+    if (this._expensiveProcessTimer) {
+      clearTimeout(this._expensiveProcessTimer);
+      this._expensiveProcessTimer = null;
+    }
+    this._pendingCleanData = '';
+  }
+
+  private _handleJsonMessage(cleanLine: string, rawLine: string): void {
+    try {
+      const msg = JSON.parse(cleanLine) as ClaudeMessage;
+      this._messages.push(msg);
+      this.emit('message', msg);
+
+      // Trim messages array for long-running sessions
+      if (this._messages.length > MAX_MESSAGES) {
+        this._messages = this._messages.slice(-Math.floor(MAX_MESSAGES * 0.8));
+      }
+
+      // Extract Claude session ID from messages (can be in any message type)
+      // Support both sessionId (camelCase) and session_id (snake_case)
+      const msgSessionId =
+        ((msg as unknown as Record<string, unknown>).sessionId as string | undefined) ?? msg.session_id;
+      if (msgSessionId && !this._claudeSessionId) {
+        this._claudeSessionId = msgSessionId;
+      }
+
+      // Process message for task tracking
+      this._taskTracker.processMessage(msg);
+
+      if (msg.type === 'assistant' && msg.message?.content) {
+        for (const block of msg.message.content) {
+          if (block.type === 'text' && block.text) {
+            this._textOutput.append(block.text);
+          }
+        }
+        // Track tokens from usage (with validation)
+        if (msg.message.usage) {
+          const inputDelta = msg.message.usage.input_tokens || 0;
+          const outputDelta = msg.message.usage.output_tokens || 0;
+
+          // Sanity check: max 100k tokens per message (generous limit)
+          const MAX_TOKENS_PER_MESSAGE = 100_000;
+          if (inputDelta > 0 && inputDelta <= MAX_TOKENS_PER_MESSAGE) {
+            this._totalInputTokens += inputDelta;
+          }
+          if (outputDelta > 0 && outputDelta <= MAX_TOKENS_PER_MESSAGE) {
+            this._totalOutputTokens += outputDelta;
+          }
+
+          // Check if we should auto-compact or auto-clear
+          this._autoOps.checkAutoCompact();
+          this._autoOps.checkAutoClear();
+        }
+      }
+
+      if (msg.type === 'result' && msg.total_cost_usd) {
+        this._totalCost = msg.total_cost_usd;
+      }
+    } catch (parseErr) {
+      // Not JSON, just regular output - this is expected for non-JSON lines
+      console.debug(
+        '[Session] Line not JSON (expected for text output):',
+        parseErr instanceof Error ? parseErr.message : parseErr
+      );
+      this._textOutput.append(rawLine + '\n');
+    }
+  }
+
   private processOutput(data: string): void {
     // Early return if session is stopped to prevent any processing or timer creation
     if (this._isStopped) return;
@@ -1606,64 +1664,7 @@ export class Session extends EventEmitter {
       const cleanLine = trimmed.replace(ANSI_ESCAPE_PATTERN_FULL, '');
 
       if (cleanLine.startsWith('{') && cleanLine.endsWith('}')) {
-        try {
-          const msg = JSON.parse(cleanLine) as ClaudeMessage;
-          this._messages.push(msg);
-          this.emit('message', msg);
-
-          // Trim messages array for long-running sessions
-          if (this._messages.length > MAX_MESSAGES) {
-            this._messages = this._messages.slice(-Math.floor(MAX_MESSAGES * 0.8));
-          }
-
-          // Extract Claude session ID from messages (can be in any message type)
-          // Support both sessionId (camelCase) and session_id (snake_case)
-          const msgSessionId =
-            ((msg as unknown as Record<string, unknown>).sessionId as string | undefined) ?? msg.session_id;
-          if (msgSessionId && !this._claudeSessionId) {
-            this._claudeSessionId = msgSessionId;
-          }
-
-          // Process message for task tracking
-          this._taskTracker.processMessage(msg);
-
-          if (msg.type === 'assistant' && msg.message?.content) {
-            for (const block of msg.message.content) {
-              if (block.type === 'text' && block.text) {
-                this._textOutput.append(block.text);
-              }
-            }
-            // Track tokens from usage (with validation)
-            if (msg.message.usage) {
-              const inputDelta = msg.message.usage.input_tokens || 0;
-              const outputDelta = msg.message.usage.output_tokens || 0;
-
-              // Sanity check: max 100k tokens per message (generous limit)
-              const MAX_TOKENS_PER_MESSAGE = 100_000;
-              if (inputDelta > 0 && inputDelta <= MAX_TOKENS_PER_MESSAGE) {
-                this._totalInputTokens += inputDelta;
-              }
-              if (outputDelta > 0 && outputDelta <= MAX_TOKENS_PER_MESSAGE) {
-                this._totalOutputTokens += outputDelta;
-              }
-
-              // Check if we should auto-compact or auto-clear
-              this._autoOps.checkAutoCompact();
-              this._autoOps.checkAutoClear();
-            }
-          }
-
-          if (msg.type === 'result' && msg.total_cost_usd) {
-            this._totalCost = msg.total_cost_usd;
-          }
-        } catch (parseErr) {
-          // Not JSON, just regular output - this is expected for non-JSON lines
-          console.debug(
-            '[Session] Line not JSON (expected for text output):',
-            parseErr instanceof Error ? parseErr.message : parseErr
-          );
-          this._textOutput.append(line + '\n');
-        }
+        this._handleJsonMessage(cleanLine, line);
       } else if (trimmed) {
         this._textOutput.append(line + '\n');
       }
@@ -1955,7 +1956,7 @@ export class Session extends EventEmitter {
     this._status = 'busy';
     this._lastActivityAt = Date.now();
     this.runPrompt(input).catch((err) => {
-      const errorMsg = err instanceof Error ? err.message : String(err);
+      const errorMsg = getErrorMessage(err);
       // Clean up task state so the task queue doesn't get stuck
       if (this._currentTaskId) {
         const taskId = this._currentTaskId;
@@ -2030,43 +2031,7 @@ export class Session extends EventEmitter {
     // Set stopped flag first to prevent new timers from being created
     this._isStopped = true;
 
-    // Clear activity timeout to prevent memory leak
-    if (this.activityTimeout) {
-      clearTimeout(this.activityTimeout);
-      this.activityTimeout = null;
-    }
-
-    // Clear line buffer flush timer
-    if (this._lineBufferFlushTimer) {
-      clearTimeout(this._lineBufferFlushTimer);
-      this._lineBufferFlushTimer = null;
-    }
-
-    // Destroy auto-compact/auto-clear automation (clears its timers)
-    this._autoOps.destroy();
-
-    // Clear prompt check timers
-    if (this._promptCheckInterval) {
-      clearInterval(this._promptCheckInterval);
-      this._promptCheckInterval = null;
-    }
-    if (this._promptCheckTimeout) {
-      clearTimeout(this._promptCheckTimeout);
-      this._promptCheckTimeout = null;
-    }
-
-    // Clear shell idle timer
-    if (this._shellIdleTimer) {
-      clearTimeout(this._shellIdleTimer);
-      this._shellIdleTimer = null;
-    }
-
-    // Clear expensive processing timer
-    if (this._expensiveProcessTimer) {
-      clearTimeout(this._expensiveProcessTimer);
-      this._expensiveProcessTimer = null;
-    }
-    this._pendingCleanData = '';
+    this._clearAllTimers();
 
     // Immediately cleanup Promise callbacks to prevent orphaned references
     // during the rest of stop() processing (e.g., if mux kill times out)

src/state-store.ts

@@ -116,6 +116,26 @@ export class StateStore {
     this.loadRalphStates();
   }
 
+  private _mergeWithInitialState(parsed: Partial<AppState>): AppState {
+    const initial = createInitialState();
+    return {
+      ...initial,
+      ...parsed,
+      sessions: { ...parsed.sessions },
+      tasks: { ...parsed.tasks },
+      ralphLoop: { ...initial.ralphLoop, ...parsed.ralphLoop },
+      config: { ...initial.config, ...parsed.config },
+    };
+  }
+
+  private _resetCircuitBreaker(): void {
+    this.consecutiveSaveFailures = 0;
+    if (this.circuitBreakerOpen) {
+      console.log('[StateStore] Circuit breaker CLOSED - save succeeded');
+      this.circuitBreakerOpen = false;
+    }
+  }
+
   private ensureDir(): void {
     const dir = dirname(this.filePath);
     if (!existsSync(dir)) {
@@ -132,15 +152,7 @@ export class StateStore {
         if (existsSync(path)) {
           const data = readFileSync(path, 'utf-8');
           const parsed = JSON.parse(data) as Partial<AppState>;
-          const initial = createInitialState();
-          const result = {
-            ...initial,
-            ...parsed,
-            sessions: { ...parsed.sessions },
-            tasks: { ...parsed.tasks },
-            ralphLoop: { ...initial.ralphLoop, ...parsed.ralphLoop },
-            config: { ...initial.config, ...parsed.config },
-          };
+          const result = this._mergeWithInitialState(parsed);
           if (path !== this.filePath) {
             console.warn(`[StateStore] Recovered state from backup: ${path}`);
           }
@@ -195,16 +207,7 @@ export class StateStore {
    * Only dirty sessions are re-serialized; clean sessions use cached JSON fragments.
    */
   private assembleStateJson(): string {
-    // Re-serialize dirty sessions and update cache
-    for (const id of this.dirtySessions) {
-      const session = this.state.sessions[id];
-      if (session) {
-        this.cachedSessionJsons.set(id, JSON.stringify(session));
-      } else {
-        this.cachedSessionJsons.delete(id);
-      }
-    }
-    this.dirtySessions.clear();
+    this.updateDirtySessionCache();
 
     // Build sessions object from cached fragments
     const sessionParts: string[] = [];
@@ -218,6 +221,25 @@ export class StateStore {
       sessionParts.push(`${JSON.stringify(id)}:${json}`);
     }
 
+    this.pruneStaleCacheEntries();
+
+    return this.buildPartialJson(sessionParts);
+  }
+
+  private updateDirtySessionCache(): void {
+    // Re-serialize dirty sessions and update cache
+    for (const id of this.dirtySessions) {
+      const session = this.state.sessions[id];
+      if (session) {
+        this.cachedSessionJsons.set(id, JSON.stringify(session));
+      } else {
+        this.cachedSessionJsons.delete(id);
+      }
+    }
+    this.dirtySessions.clear();
+  }
+
+  private pruneStaleCacheEntries(): void {
     // Prune stale cache entries (sessions removed via direct state mutation)
     if (this.cachedSessionJsons.size > Object.keys(this.state.sessions).length) {
       for (const cachedId of this.cachedSessionJsons.keys()) {
@@ -226,7 +248,9 @@ export class StateStore {
         }
       }
     }
+  }
 
+  private buildPartialJson(sessionParts: string[]): string {
     // Build final JSON: sessions from cache, everything else re-serialized (tiny)
     const sessionsJson = `{${sessionParts.join(',')}}`;
 
@@ -249,6 +273,28 @@ export class StateStore {
     return `{${parts.join(',')}}`;
   }
 
+  private serializeState(): string | null {
+    try {
+      return this.assembleStateJson();
+    } catch (assembleErr) {
+      // Fallback to full serialization if incremental assembly fails
+      console.warn('[StateStore] assembleStateJson failed, falling back to full serialize:', assembleErr);
+      this.cachedSessionJsons.clear();
+      this.dirtySessions.clear();
+      try {
+        return JSON.stringify(this.state);
+      } catch (err) {
+        console.error('[StateStore] Failed to serialize state (circular reference or invalid data):', err);
+        this.consecutiveSaveFailures++;
+        if (this.consecutiveSaveFailures >= MAX_CONSECUTIVE_FAILURES) {
+          console.error('[StateStore] Circuit breaker OPEN - serialization failing repeatedly');
+          this.circuitBreakerOpen = true;
+        }
+        return null;
+      }
+    }
+  }
+
   private async _doSaveAsync(): Promise<void> {
     this.saveDeb.cancel();
     if (!this.dirty) {
@@ -265,28 +311,10 @@ export class StateStore {
 
     const tempPath = this.filePath + '.tmp';
     const backupPath = this.filePath + '.bak';
-    let json: string;
 
     // Step 1: Serialize state (validates it's JSON-safe)
-    try {
-      json = this.assembleStateJson();
-    } catch (assembleErr) {
-      // Fallback to full serialization if incremental assembly fails
-      console.warn('[StateStore] assembleStateJson failed, falling back to full serialize:', assembleErr);
-      this.cachedSessionJsons.clear();
-      this.dirtySessions.clear();
-      try {
-        json = JSON.stringify(this.state);
-      } catch (err) {
-        console.error('[StateStore] Failed to serialize state (circular reference or invalid data):', err);
-        this.consecutiveSaveFailures++;
-        if (this.consecutiveSaveFailures >= MAX_CONSECUTIVE_FAILURES) {
-          console.error('[StateStore] Circuit breaker OPEN - serialization failing repeatedly');
-          this.circuitBreakerOpen = true;
-        }
-        return;
-      }
-    }
+    const json = this.serializeState();
+    if (json === null) return;
 
     // Clear dirty flag BEFORE async I/O so mutations during write re-set it.
     // The state snapshot is already captured in `json` above.
@@ -305,11 +333,7 @@ export class StateStore {
       await writeFile(tempPath, json, 'utf-8');
       await rename(tempPath, this.filePath);
 
-      this.consecutiveSaveFailures = 0;
-      if (this.circuitBreakerOpen) {
-        console.log('[StateStore] Circuit breaker CLOSED - save succeeded');
-        this.circuitBreakerOpen = false;
-      }
+      this._resetCircuitBreaker();
     } catch (err) {
       console.error('[StateStore] Failed to write state file:', err);
       // Re-mark dirty so the data is retried on the next save cycle
@@ -351,27 +375,9 @@ export class StateStore {
 
     const tempPath = this.filePath + '.tmp';
     const backupPath = this.filePath + '.bak';
-    let json: string;
 
-    try {
-      json = this.assembleStateJson();
-    } catch (assembleErr) {
-      // Fallback to full serialization if incremental assembly fails
-      console.warn('[StateStore] assembleStateJson failed, falling back to full serialize:', assembleErr);
-      this.cachedSessionJsons.clear();
-      this.dirtySessions.clear();
-      try {
-        json = JSON.stringify(this.state);
-      } catch (err) {
-        console.error('[StateStore] Failed to serialize state (circular reference or invalid data):', err);
-        this.consecutiveSaveFailures++;
-        if (this.consecutiveSaveFailures >= MAX_CONSECUTIVE_FAILURES) {
-          console.error('[StateStore] Circuit breaker OPEN - serialization failing repeatedly');
-          this.circuitBreakerOpen = true;
-        }
-        return;
-      }
-    }
+    const json = this.serializeState();
+    if (json === null) return;
 
     // Backup via atomic copy (avoids reading entire file into memory)
     try {
@@ -387,11 +393,7 @@ export class StateStore {
       renameSync(tempPath, this.filePath);
       // Clear dirty flag only AFTER successful write
       this.dirty = false;
-      this.consecutiveSaveFailures = 0;
-      if (this.circuitBreakerOpen) {
-        console.log('[StateStore] Circuit breaker CLOSED - save succeeded');
-        this.circuitBreakerOpen = false;
-      }
+      this._resetCircuitBreaker();
     } catch (err) {
       console.error('[StateStore] Failed to write state file:', err);
       this.consecutiveSaveFailures++;
@@ -417,15 +419,7 @@ export class StateStore {
       if (existsSync(backupPath)) {
         const backupContent = readFileSync(backupPath, 'utf-8');
         const parsed = JSON.parse(backupContent) as Partial<AppState>;
-        const initial = createInitialState();
-        this.state = {
-          ...initial,
-          ...parsed,
-          sessions: { ...parsed.sessions },
-          tasks: { ...parsed.tasks },
-          ralphLoop: { ...initial.ralphLoop, ...parsed.ralphLoop },
-          config: { ...initial.config, ...parsed.config },
-        };
+        this.state = this._mergeWithInitialState(parsed);
         console.log('[StateStore] Successfully recovered state from backup');
         // Reset circuit breaker after successful recovery
         this.circuitBreakerOpen = false;

src/subagent-watcher.ts

@@ -222,6 +222,83 @@ export class SubagentWatcher extends EventEmitter {
     return INTERNAL_AGENT_PATTERNS.some((pattern) => pattern.test(description));
   }
 
+  /**
+   * Mark a subagent as completed: clear PID, set status, clean up pending tool calls, emit event.
+   */
+  private markSubagentAsCompleted(info: SubagentInfo): void {
+    info.pid = undefined;
+    info.status = 'completed';
+    this.pendingToolCalls.delete(info.agentId);
+    this.emit('subagent:completed', info);
+  }
+
+  /**
+   * Extract text from message content, handling both string and array formats.
+   * For array content, returns the text from the first 'text' block.
+   */
+  private extractFirstTextContent(
+    content: string | Array<{ type: string; text?: string }> | undefined
+  ): string | undefined {
+    if (!content) return undefined;
+    if (typeof content === 'string') {
+      const trimmed = content.trim();
+      return trimmed.length > 0 ? trimmed : undefined;
+    }
+    if (Array.isArray(content)) {
+      const firstContent = content[0];
+      if (firstContent?.type === 'text' && firstContent.text) {
+        const trimmed = firstContent.text.trim();
+        return trimmed.length > 0 ? trimmed : undefined;
+      }
+    }
+    return undefined;
+  }
+
+  /**
+   * Process a tool_result content block: look up pending tool call, emit tool_result event.
+   */
+  private emitToolResult(
+    content: { tool_use_id: string; content?: string | Array<{ type: string; text?: string }>; is_error?: boolean },
+    agentId: string,
+    sessionId: string,
+    timestamp: string
+  ): void {
+    const resultContent = this.extractToolResultContent(content.content);
+    const agentPendingCalls = this.pendingToolCalls.get(agentId);
+    const pendingCall = agentPendingCalls?.get(content.tool_use_id);
+    const toolName = pendingCall?.toolName;
+    // Delete after lookup to prevent memory leak
+    agentPendingCalls?.delete(content.tool_use_id);
+
+    const toolResult: SubagentToolResult = {
+      agentId,
+      sessionId,
+      timestamp,
+      toolUseId: content.tool_use_id,
+      tool: toolName,
+      preview: resultContent.substring(0, MESSAGE_TEXT_LIMIT),
+      contentLength: resultContent.length,
+      isError: content.is_error || false,
+    };
+    this.emit('subagent:tool_result', toolResult);
+  }
+
+  /**
+   * Find the oldest inactive (non-active) agent for LRU eviction.
+   * Returns the agent ID of the oldest inactive agent, or null if all are active.
+   */
+  private findOldestInactiveAgent(): string | null {
+    let oldestId: string | null = null;
+    let oldestTime = Infinity;
+    for (const [id, existing] of this.agentInfo) {
+      if (existing.status !== 'active' && existing.lastActivityAt < oldestTime) {
+        oldestTime = existing.lastActivityAt;
+        oldestId = id;
+      }
+    }
+    return oldestId;
+  }
+
   /**
    * Extract short model identifier from full model name
    */
@@ -307,10 +384,7 @@ export class SubagentWatcher extends EventEmitter {
 
               const alive = this.checkSubagentAliveFromPidMap(info, pidMap);
               if (!alive) {
-                info.pid = undefined;
-                info.status = 'completed';
-                this.pendingToolCalls.delete(info.agentId);
-                this.emit('subagent:completed', info);
+                this.markSubagentAsCompleted(info);
               }
             }
           }
@@ -677,10 +751,7 @@ export class SubagentWatcher extends EventEmitter {
       const pid = await this.findSubagentProcess(info.sessionId);
       if (pid) {
         process.kill(pid, 'SIGTERM');
-        info.pid = undefined;
-        info.status = 'completed';
-        this.pendingToolCalls.delete(info.agentId);
-        this.emit('subagent:completed', info);
+        this.markSubagentAsCompleted(info);
         return true;
       }
     } catch {
@@ -688,10 +759,7 @@ export class SubagentWatcher extends EventEmitter {
     }
 
     // Mark as completed even if we couldn't find the process
-    info.pid = undefined;
-    info.status = 'completed';
-    this.pendingToolCalls.delete(info.agentId);
-    this.emit('subagent:completed', info);
+    this.markSubagentAsCompleted(info);
     return true;
   }
 
@@ -843,19 +911,9 @@ export class SubagentWatcher extends EventEmitter {
         }
       } else if (entry.type === 'user' && entry.message?.content) {
         // Handle both string and array content formats
-        if (typeof entry.message.content === 'string') {
-          const text = entry.message.content.trim();
-          if (text.length < 100 && !text.includes('{')) {
-            lines.push(`${this.formatTime(entry.timestamp)} 📥 User: ${text.substring(0, USER_TEXT_PREVIEW_LENGTH)}`);
-          }
-        } else {
-          const firstContent = entry.message.content[0];
-          if (firstContent?.type === 'text' && firstContent.text) {
-            const text = firstContent.text.trim();
-            if (text.length < 100 && !text.includes('{')) {
-              lines.push(`${this.formatTime(entry.timestamp)} 📥 User: ${text.substring(0, USER_TEXT_PREVIEW_LENGTH)}`);
-            }
-          }
+        const text = this.extractFirstTextContent(entry.message.content);
+        if (text && text.length < 100 && !text.includes('{')) {
+          lines.push(`${this.formatTime(entry.timestamp)} 📥 User: ${text.substring(0, USER_TEXT_PREVIEW_LENGTH)}`);
         }
       }
     }
@@ -930,6 +988,24 @@ export class SubagentWatcher extends EventEmitter {
     return truncated.replace(/[.!?,:\s]+$/, '');
   }
 
+  private async _resolveDescription(
+    projectHash: string,
+    sessionId: string,
+    agentId: string,
+    filePath: string,
+    fallbackText?: string
+  ): Promise<string | undefined> {
+    // First try parent transcript (most reliable)
+    const fromParent = await this.extractDescriptionFromParentTranscript(projectHash, sessionId, agentId);
+    if (fromParent) return fromParent;
+
+    // Fallback: inline text (from processEntry) or file extraction
+    if (fallbackText) {
+      return this.extractSmartTitle(fallbackText);
+    }
+    return this.extractDescriptionFromFile(filePath);
+  }
+
   /**
    * Extract the short description from the parent session's transcript.
    * This is the most reliable method because it reads the actual Task tool result
@@ -1027,15 +1103,7 @@ export class SubagentWatcher extends EventEmitter {
           try {
             const entry = JSON.parse(line);
             if (entry.type === 'user' && entry.message?.content) {
-              let text: string | undefined;
-              if (typeof entry.message.content === 'string') {
-                text = entry.message.content.trim();
-              } else if (Array.isArray(entry.message.content)) {
-                const firstContent = entry.message.content[0];
-                if (firstContent?.type === 'text' && firstContent.text) {
-                  text = firstContent.text.trim();
-                }
-              }
+              const text = this.extractFirstTextContent(entry.message.content);
               if (text) {
                 resolved = true;
                 rl.close();
@@ -1195,18 +1263,13 @@ export class SubagentWatcher extends EventEmitter {
 
       // Retry description extraction if missing (race condition fix)
       if (!existingInfo.description) {
-        // First try parent transcript (most reliable)
-        let extractedDescription = await this.extractDescriptionFromParentTranscript(
+        const extractedDescription = await this._resolveDescription(
           existingInfo.projectHash,
           existingInfo.sessionId,
-          agentId
+          agentId,
+          filePath
         );
-        // Fallback to subagent file
-        if (!extractedDescription) {
-          extractedDescription = await this.extractDescriptionFromFile(filePath);
-        }
         if (extractedDescription) {
-          // Check if this is an internal agent - if so, remove it
           if (this.isInternalAgent(extractedDescription)) {
             this.removeAgent(agentId);
             return;
@@ -1257,13 +1320,7 @@ export class SubagentWatcher extends EventEmitter {
     }
 
     // Extract description - prefer reading from parent transcript (most reliable)
-    // The parent transcript has the exact Task tool call with description parameter
-    let description = await this.extractDescriptionFromParentTranscript(projectHash, sessionId, agentId);
-
-    // Fallback: extract a smart title from the subagent's prompt if parent lookup failed
-    if (!description) {
-      description = await this.extractDescriptionFromFile(filePath);
-    }
+    const description = await this._resolveDescription(projectHash, sessionId, agentId, filePath);
 
     // Skip internal Claude Code agents (e.g., suggestion mode) - not real subagents
     if (this.isInternalAgent(description)) {
@@ -1286,14 +1343,7 @@ export class SubagentWatcher extends EventEmitter {
 
     // Enforce MAX_TRACKED_AGENTS during insertion — evict oldest inactive agent
     if (this.agentInfo.size >= MAX_TRACKED_AGENTS) {
-      let oldestId: string | null = null;
-      let oldestTime = Infinity;
-      for (const [id, existing] of this.agentInfo) {
-        if (existing.status !== 'active' && existing.lastActivityAt < oldestTime) {
-          oldestTime = existing.lastActivityAt;
-          oldestId = id;
-        }
-      }
+      const oldestId = this.findOldestInactiveAgent();
       if (oldestId) {
         this.removeAgent(oldestId);
       }
@@ -1363,51 +1413,11 @@ export class SubagentWatcher extends EventEmitter {
   private async processEntry(entry: SubagentTranscriptEntry, agentId: string, sessionId: string): Promise<void> {
     const info = this.agentInfo.get(agentId);
 
-    // Extract model from assistant messages (first one sets the model)
-    if (info && entry.type === 'assistant' && entry.message?.model && !info.model) {
-      info.model = entry.message.model;
-      info.modelShort = this.extractModelShort(entry.message.model);
-      this.emit('subagent:updated', info);
-    }
+    if (info) {
+      this._processModelInfo(entry, info);
+      this._processTokenInfo(entry, info);
 
-    // Aggregate token usage from messages
-    if (info && entry.message?.usage) {
-      if (entry.message.usage.input_tokens) {
-        info.totalInputTokens = (info.totalInputTokens || 0) + entry.message.usage.input_tokens;
-      }
-      if (entry.message.usage.output_tokens) {
-        info.totalOutputTokens = (info.totalOutputTokens || 0) + entry.message.usage.output_tokens;
-      }
-    }
-
-    // Check if this is first user message and description is missing
-    if (info && !info.description && entry.type === 'user' && entry.message?.content) {
-      // First try parent transcript (most reliable)
-      let description = await this.extractDescriptionFromParentTranscript(info.projectHash, info.sessionId, agentId);
-      // Fallback: extract smart title from the prompt content
-      if (!description) {
-        let text: string | undefined;
-        if (typeof entry.message.content === 'string') {
-          text = entry.message.content.trim();
-        } else if (Array.isArray(entry.message.content)) {
-          const firstContent = entry.message.content[0];
-          if (firstContent?.type === 'text' && firstContent.text) {
-            text = firstContent.text.trim();
-          }
-        }
-        if (text) {
-          description = this.extractSmartTitle(text);
-        }
-      }
-      if (description) {
-        // Check if this is an internal agent - if so, remove it
-        if (this.isInternalAgent(description)) {
-          this.removeAgent(agentId);
-          return;
-        }
-        info.description = description;
-        this.emit('subagent:updated', info);
-      }
+      if (await this._processDescription(entry, agentId, info)) return;
     }
 
     if (entry.type === 'progress' && entry.data) {
@@ -1418,7 +1428,6 @@ export class SubagentWatcher extends EventEmitter {
         progressType: entry.data.type,
         query: entry.data.query,
         resultCount: entry.data.resultCount,
-        // Extract hook event info if present
         hookEvent: entry.data.hookEvent,
         hookName:
           entry.data.hookName ||
@@ -1428,139 +1437,166 @@ export class SubagentWatcher extends EventEmitter {
       };
       this.emit('subagent:progress', progress);
     } else if (entry.type === 'assistant' && entry.message?.content) {
-      // Handle both string and array content formats
-      if (typeof entry.message.content === 'string') {
-        const text = entry.message.content.trim();
-        if (text.length > 0) {
-          const message: SubagentMessage = {
+      this._processAssistantContent(entry, agentId, sessionId);
+    } else if (entry.type === 'user' && entry.message?.content) {
+      this._processUserContent(entry, agentId, sessionId);
+    }
+  }
+
+  private _processModelInfo(entry: SubagentTranscriptEntry, agent: SubagentInfo): void {
+    if (entry.type === 'assistant' && entry.message?.model && !agent.model) {
+      agent.model = entry.message.model;
+      agent.modelShort = this.extractModelShort(entry.message.model);
+      this.emit('subagent:updated', agent);
+    }
+  }
+
+  private _processTokenInfo(entry: SubagentTranscriptEntry, agent: SubagentInfo): void {
+    if (!entry.message?.usage) return;
+    if (entry.message.usage.input_tokens) {
+      agent.totalInputTokens = (agent.totalInputTokens || 0) + entry.message.usage.input_tokens;
+    }
+    if (entry.message.usage.output_tokens) {
+      agent.totalOutputTokens = (agent.totalOutputTokens || 0) + entry.message.usage.output_tokens;
+    }
+  }
+
+  private async _processDescription(
+    entry: SubagentTranscriptEntry,
+    agentId: string,
+    agent: SubagentInfo
+  ): Promise<boolean> {
+    if (agent.description || entry.type !== 'user' || !entry.message?.content) return false;
+
+    const fallbackText = this.extractFirstTextContent(entry.message.content);
+    const description = await this._resolveDescription(
+      agent.projectHash,
+      agent.sessionId,
+      agentId,
+      agent.filePath,
+      fallbackText
+    );
+    if (description) {
+      if (this.isInternalAgent(description)) {
+        this.removeAgent(agentId);
+        return true;
+      }
+      agent.description = description;
+      this.emit('subagent:updated', agent);
+    }
+    return false;
+  }
+
+  private _processAssistantContent(entry: SubagentTranscriptEntry, agentId: string, sessionId: string): void {
+    const messageContent = entry.message!.content;
+    if (typeof messageContent === 'string') {
+      const text = messageContent.trim();
+      if (text.length > 0) {
+        const message: SubagentMessage = {
+          agentId,
+          sessionId,
+          timestamp: entry.timestamp,
+          role: 'assistant',
+          text: text.substring(0, MESSAGE_TEXT_LIMIT),
+        };
+        this.emit('subagent:message', message);
+      }
+    } else {
+      for (const content of messageContent) {
+        if (content.type === 'tool_use' && content.name) {
+          // Store toolUseId for linking to results, with timestamp for TTL cleanup
+          if (content.id) {
+            if (!this.pendingToolCalls.has(agentId)) {
+              this.pendingToolCalls.set(agentId, new Map());
+            }
+            const agentCalls = this.pendingToolCalls.get(agentId)!;
+            // Enforce size limit to prevent memory leak from rapid tool calls
+            if (agentCalls.size >= MAX_PENDING_TOOL_CALLS) {
+              // FIFO eviction: delete first (oldest) entry using Map insertion order
+              const firstKey = agentCalls.keys().next().value;
+              if (firstKey !== undefined) agentCalls.delete(firstKey);
+            }
+            agentCalls.set(content.id, {
+              toolName: content.name,
+              timestamp: Date.now(),
+            });
+          }
+
+          const toolCall: SubagentToolCall = {
             agentId,
             sessionId,
             timestamp: entry.timestamp,
-            role: 'assistant',
-            text: text.substring(0, MESSAGE_TEXT_LIMIT),
+            tool: content.name,
+            input: this.getTruncatedInput(content.name, content.input || {}),
+            toolUseId: content.id,
+            fullInput: content.input || {},
           };
-          this.emit('subagent:message', message);
-        }
-      } else {
-        for (const content of entry.message.content) {
-          if (content.type === 'tool_use' && content.name) {
-            // Store toolUseId for linking to results, with timestamp for TTL cleanup
-            if (content.id) {
-              if (!this.pendingToolCalls.has(agentId)) {
-                this.pendingToolCalls.set(agentId, new Map());
-              }
-              const agentCalls = this.pendingToolCalls.get(agentId)!;
-              // Enforce size limit to prevent memory leak from rapid tool calls
-              if (agentCalls.size >= MAX_PENDING_TOOL_CALLS) {
-                // FIFO eviction: delete first (oldest) entry using Map insertion order
-                const firstKey = agentCalls.keys().next().value;
-                if (firstKey !== undefined) agentCalls.delete(firstKey);
-              }
-              agentCalls.set(content.id, {
-                toolName: content.name,
-                timestamp: Date.now(),
-              });
-            }
+          this.emit('subagent:tool_call', toolCall);
 
-            const toolCall: SubagentToolCall = {
+          // Update tool call count
+          const agentInfo = this.agentInfo.get(agentId);
+          if (agentInfo) {
+            agentInfo.toolCallCount++;
+          }
+        } else if (content.type === 'tool_result' && content.tool_use_id) {
+          this.emitToolResult(
+            { tool_use_id: content.tool_use_id, content: content.content, is_error: content.is_error },
+            agentId,
+            sessionId,
+            entry.timestamp
+          );
+        } else if (content.type === 'text' && content.text) {
+          const text = content.text.trim();
+          if (text.length > 0) {
+            const message: SubagentMessage = {
               agentId,
               sessionId,
               timestamp: entry.timestamp,
-              tool: content.name,
-              input: this.getTruncatedInput(content.name, content.input || {}),
-              toolUseId: content.id,
-              fullInput: content.input || {},
+              role: 'assistant',
+              text: text.substring(0, MESSAGE_TEXT_LIMIT),
             };
-            this.emit('subagent:tool_call', toolCall);
-
-            // Update tool call count
-            const agentInfo = this.agentInfo.get(agentId);
-            if (agentInfo) {
-              agentInfo.toolCallCount++;
-            }
-          } else if (content.type === 'tool_result' && content.tool_use_id) {
-            // Extract tool result
-            const resultContent = this.extractToolResultContent(content.content);
-            const agentPendingCalls = this.pendingToolCalls.get(agentId);
-            const pendingCall = agentPendingCalls?.get(content.tool_use_id);
-            const toolName = pendingCall?.toolName;
-            // Delete after lookup to prevent memory leak
-            agentPendingCalls?.delete(content.tool_use_id);
-
-            const toolResult: SubagentToolResult = {
-              agentId,
-              sessionId,
-              timestamp: entry.timestamp,
-              toolUseId: content.tool_use_id,
-              tool: toolName,
-              preview: resultContent.substring(0, MESSAGE_TEXT_LIMIT),
-              contentLength: resultContent.length,
-              isError: content.is_error || false,
-            };
-            this.emit('subagent:tool_result', toolResult);
-          } else if (content.type === 'text' && content.text) {
-            const text = content.text.trim();
-            if (text.length > 0) {
-              const message: SubagentMessage = {
-                agentId,
-                sessionId,
-                timestamp: entry.timestamp,
-                role: 'assistant',
-                text: text.substring(0, MESSAGE_TEXT_LIMIT), // Limit text length
-              };
-              this.emit('subagent:message', message);
-            }
+            this.emit('subagent:message', message);
           }
         }
       }
-    } else if (entry.type === 'user' && entry.message?.content) {
-      // Handle both string and array content formats - also check for tool_result in user messages
-      if (typeof entry.message.content === 'string') {
-        const userText = entry.message.content.trim();
-        if (userText.length > 0 && userText.length < 500) {
-          const message: SubagentMessage = {
+    }
+  }
+
+  private _processUserContent(entry: SubagentTranscriptEntry, agentId: string, sessionId: string): void {
+    const messageContent = entry.message!.content;
+    if (typeof messageContent === 'string') {
+      const userText = messageContent.trim();
+      if (userText.length > 0 && userText.length < 500) {
+        const message: SubagentMessage = {
+          agentId,
+          sessionId,
+          timestamp: entry.timestamp,
+          role: 'user',
+          text: userText,
+        };
+        this.emit('subagent:message', message);
+      }
+    } else {
+      // Check for tool_result blocks in user messages (common pattern)
+      for (const content of messageContent) {
+        if (content.type === 'tool_result' && content.tool_use_id) {
+          this.emitToolResult(
+            { tool_use_id: content.tool_use_id, content: content.content, is_error: content.is_error },
             agentId,
             sessionId,
-            timestamp: entry.timestamp,
-            role: 'user',
-            text: userText,
-          };
-          this.emit('subagent:message', message);
-        }
-      } else {
-        // Check for tool_result blocks in user messages (common pattern)
-        for (const content of entry.message.content) {
-          if (content.type === 'tool_result' && content.tool_use_id) {
-            const resultContent = this.extractToolResultContent(content.content);
-            const agentPendingCalls = this.pendingToolCalls.get(agentId);
-            const pendingCall = agentPendingCalls?.get(content.tool_use_id);
-            const toolName = pendingCall?.toolName;
-            // Delete after lookup to prevent memory leak
-            agentPendingCalls?.delete(content.tool_use_id);
-
-            const toolResult: SubagentToolResult = {
+            entry.timestamp
+          );
+        } else if (content.type === 'text' && content.text) {
+          const userText = content.text.trim();
+          if (userText.length > 0 && userText.length < 500) {
+            const message: SubagentMessage = {
               agentId,
               sessionId,
               timestamp: entry.timestamp,
-              toolUseId: content.tool_use_id,
-              tool: toolName,
-              preview: resultContent.substring(0, MESSAGE_TEXT_LIMIT),
-              contentLength: resultContent.length,
-              isError: content.is_error || false,
+              role: 'user',
+              text: userText,
             };
-            this.emit('subagent:tool_result', toolResult);
-          } else if (content.type === 'text' && content.text) {
-            const userText = content.text.trim();
-            if (userText.length > 0 && userText.length < 500) {
-              const message: SubagentMessage = {
-                agentId,
-                sessionId,
-                timestamp: entry.timestamp,
-                role: 'user',
-                text: userText,
-              };
-              this.emit('subagent:message', message);
-            }
+            this.emit('subagent:message', message);
           }
         }
       }

src/tmux-manager.ts

@@ -98,6 +98,9 @@ const LEGACY_MUX_NAME_PATTERN = /^claudeman-[a-f0-9-]+$/;
 /** Regex to validate tmux pane targets (e.g., "%0", "%1", "0", "1") */
 const SAFE_PANE_TARGET_PATTERN = /^(%\d+|\d+)$/;
 
+/** Characters unsafe in paths — shell metacharacters, quotes, and control chars */
+const UNSAFE_PATH_CHARS = /[;&|$`(){}<>'"\n\r]/;
+
 /**
  * Validates that a session name contains only safe characters.
  * Prevents command injection via malformed session IDs.
@@ -111,23 +114,7 @@ function isValidMuxName(name: string): boolean {
  * Prevents command injection via malformed paths.
  */
 function isValidPath(path: string): boolean {
-  if (
-    path.includes(';') ||
-    path.includes('&') ||
-    path.includes('|') ||
-    path.includes('$') ||
-    path.includes('`') ||
-    path.includes('(') ||
-    path.includes(')') ||
-    path.includes('{') ||
-    path.includes('}') ||
-    path.includes('<') ||
-    path.includes('>') ||
-    path.includes("'") ||
-    path.includes('"') ||
-    path.includes('\n') ||
-    path.includes('\r')
-  ) {
+  if (UNSAFE_PATH_CHARS.test(path)) {
     return false;
   }
   if (path.includes('..')) {
@@ -371,6 +358,52 @@ export class TmuxManager extends EventEmitter implements TerminalMultiplexer {
     }
   }
 
+  /**
+   * Build the array of environment export commands shared by createSession() and respawnPane().
+   * Includes locale, mux markers, session identity, and API URL.
+   */
+  private buildEnvExports(sessionId: string, muxName: string, mode: SessionMode): string[] {
+    const exports = [
+      'export LANG=en_US.UTF-8',
+      'export LC_ALL=en_US.UTF-8',
+      'unset COLORTERM',
+      'export CODEMAN_MUX=1',
+      `export CODEMAN_SESSION_ID=${sessionId}`,
+      `export CODEMAN_MUX_NAME=${muxName}`,
+      `export CODEMAN_API_URL=${process.env.CODEMAN_API_URL || 'http://localhost:3000'}`,
+    ];
+    // Only unset CLAUDECODE for Claude sessions
+    if (mode === 'claude') exports.splice(2, 0, 'unset CLAUDECODE');
+    return exports;
+  }
+
+  /**
+   * Resolve the CLI binary directory and return the PATH export prefix string.
+   * Returns '' if no override is needed (shell mode) or the binary dir is not found.
+   * In createSession(), a missing binary dir throws — the caller handles that separately.
+   */
+  private buildPathExport(mode: SessionMode): { pathExport: string; dir: string | null } {
+    if (mode === 'claude') {
+      const dir = findClaudeDir();
+      return { pathExport: dir ? `export PATH="${dir}:$PATH" && ` : '', dir };
+    }
+    if (mode === 'opencode') {
+      const dir = resolveOpenCodeDir();
+      return { pathExport: dir ? `export PATH="${dir}:$PATH" && ` : '', dir };
+    }
+    return { pathExport: '', dir: null };
+  }
+
+  /**
+   * Configure OpenCode-specific environment on a tmux session.
+   * Sets sensitive API keys and config content via tmux setenv
+   * (not visible in ps output or tmux history, inherited by panes).
+   */
+  private _configureOpenCode(muxName: string, openCodeConfig?: OpenCodeConfig): void {
+    setOpenCodeEnvVars(muxName);
+    setOpenCodeConfigContent(muxName, openCodeConfig);
+  }
+
   /**
    * Creates a new tmux session wrapping Claude CLI or a shell.
    * In test mode: creates an in-memory session only (no real tmux session).
@@ -415,33 +448,15 @@ export class TmuxManager extends EventEmitter implements TerminalMultiplexer {
     }
 
     // Resolve CLI binary directory based on mode
-    let pathExport = '';
-    if (mode === 'claude') {
-      const claudeDir = findClaudeDir();
-      if (!claudeDir) {
-        throw new Error('Claude CLI not found. Install it with: curl -fsSL https://claude.ai/install.sh | bash');
-      }
-      pathExport = `export PATH="${claudeDir}:$PATH" && `;
-    } else if (mode === 'opencode') {
-      const openCodeDir = resolveOpenCodeDir();
-      if (!openCodeDir) {
-        throw new Error('OpenCode CLI not found. Install with: curl -fsSL https://opencode.ai/install | bash');
-      }
-      pathExport = `export PATH="${openCodeDir}:$PATH" && `;
+    const { pathExport, dir: cliDir } = this.buildPathExport(mode);
+    if (mode === 'claude' && !cliDir) {
+      throw new Error('Claude CLI not found. Install it with: curl -fsSL https://claude.ai/install.sh | bash');
+    }
+    if (mode === 'opencode' && !cliDir) {
+      throw new Error('OpenCode CLI not found. Install with: curl -fsSL https://opencode.ai/install | bash');
     }
 
-    const envExports = [
-      'export LANG=en_US.UTF-8',
-      'export LC_ALL=en_US.UTF-8',
-      'unset COLORTERM',
-      'export CODEMAN_MUX=1',
-      `export CODEMAN_SESSION_ID=${sessionId}`,
-      `export CODEMAN_MUX_NAME=${muxName}`,
-      `export CODEMAN_API_URL=${process.env.CODEMAN_API_URL || 'http://localhost:3000'}`,
-    ];
-    // Only unset CLAUDECODE for Claude sessions
-    if (mode === 'claude') envExports.splice(2, 0, 'unset CLAUDECODE');
-    const envExportsStr = envExports.join(' && ');
+    const envExportsStr = this.buildEnvExports(sessionId, muxName, mode).join(' && ');
 
     const baseCmd = buildSpawnCommand({
       mode,
@@ -489,8 +504,7 @@ export class TmuxManager extends EventEmitter implements TerminalMultiplexer {
       // For OpenCode: set sensitive env vars and config via tmux setenv
       // (not visible in ps output or tmux history, inherited by panes)
       if (mode === 'opencode') {
-        setOpenCodeEnvVars(muxName);
-        setOpenCodeConfigContent(muxName, openCodeConfig);
+        this._configureOpenCode(muxName, openCodeConfig);
       }
 
       // Replace the shell with the actual command (no echo in terminal)
@@ -641,26 +655,9 @@ export class TmuxManager extends EventEmitter implements TerminalMultiplexer {
     if (!isValidMuxName(muxName) || !isValidPath(workingDir)) return null;
 
     // Resolve CLI binary directory based on mode
-    let pathExport = '';
-    if (mode === 'claude') {
-      const claudeDir = findClaudeDir();
-      pathExport = claudeDir ? `export PATH="${claudeDir}:$PATH" && ` : '';
-    } else if (mode === 'opencode') {
-      const openCodeDir = resolveOpenCodeDir();
-      pathExport = openCodeDir ? `export PATH="${openCodeDir}:$PATH" && ` : '';
-    }
+    const { pathExport } = this.buildPathExport(mode);
 
-    const envExports = [
-      'export LANG=en_US.UTF-8',
-      'export LC_ALL=en_US.UTF-8',
-      'unset COLORTERM',
-      'export CODEMAN_MUX=1',
-      `export CODEMAN_SESSION_ID=${sessionId}`,
-      `export CODEMAN_MUX_NAME=${muxName}`,
-      `export CODEMAN_API_URL=${process.env.CODEMAN_API_URL || 'http://localhost:3000'}`,
-    ];
-    if (mode === 'claude') envExports.splice(2, 0, 'unset CLAUDECODE');
-    const envExportsStr = envExports.join(' && ');
+    const envExportsStr = this.buildEnvExports(sessionId, muxName, mode).join(' && ');
 
     const baseCmd = buildSpawnCommand({
       mode,
@@ -678,8 +675,7 @@ export class TmuxManager extends EventEmitter implements TerminalMultiplexer {
     try {
       // For OpenCode: set sensitive env vars via tmux setenv before respawn
       if (mode === 'opencode') {
-        setOpenCodeEnvVars(muxName);
-        setOpenCodeConfigContent(muxName, openCodeConfig);
+        this._configureOpenCode(muxName, openCodeConfig);
       }
 
       await execAsync(`tmux respawn-pane -k -t "${muxName}" bash -c ${JSON.stringify(fullCmd)}`, {

src/tunnel-manager.ts

@@ -29,6 +29,7 @@ import {
   RESTART_DELAY_MS,
   FORCE_KILL_MS,
 } from './config/tunnel-config.js';
+import { getErrorMessage } from './types.js';
 
 // ========== Types ==========
 
@@ -164,7 +165,7 @@ export class TunnelManager extends EventEmitter {
         detached: false,
       });
     } catch (err) {
-      this.emit('error', `Failed to spawn cloudflared: ${err instanceof Error ? err.message : String(err)}`);
+      this.emit('error', `Failed to spawn cloudflared: ${getErrorMessage(err)}`);
       return;
     }
 

src/web/public/app.js

@@ -432,6 +432,25 @@ class CodemanApp {
     return this._elemCache[id];
   }
 
+  // Clear a named timeout property: if (this[name]) { clearTimeout(this[name]); this[name] = null; }
+  _clearTimer(timerName) {
+    if (this[timerName]) {
+      clearTimeout(this[timerName]);
+      this[timerName] = null;
+    }
+  }
+
+  // Check if a selectSession generation is stale (a newer tab switch has started).
+  // If stale, cleans up buffer-loading state and returns true.
+  _isStaleSelect(selectGen) {
+    if (selectGen !== this._selectGeneration) {
+      if (this._isLoadingBuffer) this._finishBufferLoad();
+      this._restoringFlushedState = false;
+      return true;
+    }
+    return false;
+  }
+
   // Format token count: 1000k -> 1m, 1450k -> 1.45m, 500 -> 500
   formatTokens(count) {
     if (count >= 1000000) {
@@ -588,73 +607,43 @@ class CodemanApp {
   // ═══════════════════════════════════════════════════════════════
 
   setupEventListeners() {
+    // Keyboard shortcut lookup table — data-driven to avoid 12 separate if-blocks.
+    // Each entry: { key, altKey? (alternative key match), ctrl? (require Ctrl/Cmd),
+    //               shift? (require Shift), action }.
+    const SHORTCUTS = [
+      { key: '?', altKey: '/', ctrl: true, action: () => this.showHelp() },
+      { key: 'Enter', ctrl: true, action: () => this.quickStart() },
+      { key: 'w', ctrl: true, action: () => this.killActiveSession() },
+      { key: 'Tab', ctrl: true, action: () => this.nextSession() },
+      { key: 'k', ctrl: true, action: () => this.killAllSessions() },
+      { key: 'l', ctrl: true, action: () => this.clearTerminal() },
+      { key: 'R', ctrl: true, shift: true, action: () => this.restoreTerminalSize() },
+      { key: '=', altKey: '+', ctrl: true, action: () => this.increaseFontSize() },
+      { key: '-', ctrl: true, action: () => this.decreaseFontSize() },
+      { key: 'V', ctrl: true, shift: true, action: () => VoiceInput.toggle() },
+    ];
+
     // Use capture to handle before terminal
     document.addEventListener('keydown', (e) => {
       // Don't intercept keys during CJK IME composition
       if (e.isComposing || e.keyCode === 229) return;
 
-      // Escape - close panels and modals
+      // Escape - close panels and modals (different logic: no preventDefault, no return)
       if (e.key === 'Escape') {
         this.closeAllPanels();
         this.closeHelp();
       }
 
-      // Ctrl/Cmd + ? - help
-      if ((e.ctrlKey || e.metaKey) && (e.key === '?' || e.key === '/')) {
-        e.preventDefault();
-        this.showHelp();
-      }
-
-      // Ctrl/Cmd + Enter - quick start
-      if ((e.ctrlKey || e.metaKey) && e.key === 'Enter') {
-        e.preventDefault();
-        this.quickStart();
-      }
-
-      // Ctrl/Cmd + W - close active session
-      if ((e.ctrlKey || e.metaKey) && e.key === 'w') {
-        e.preventDefault();
-        this.killActiveSession();
-      }
-
-      // Ctrl/Cmd + Tab - next session
-      if ((e.ctrlKey || e.metaKey) && e.key === 'Tab') {
-        e.preventDefault();
-        this.nextSession();
-      }
-
-      // Ctrl/Cmd + K - kill all
-      if ((e.ctrlKey || e.metaKey) && e.key === 'k') {
-        e.preventDefault();
-        this.killAllSessions();
-      }
-
-      // Ctrl/Cmd + L - clear terminal
-      if ((e.ctrlKey || e.metaKey) && e.key === 'l') {
-        e.preventDefault();
-        this.clearTerminal();
-      }
-
-      // Ctrl/Cmd + Shift + R - restore terminal size (after mobile squeeze)
-      if ((e.ctrlKey || e.metaKey) && e.shiftKey && e.key === 'R') {
-        e.preventDefault();
-        this.restoreTerminalSize();
-      }
-
-      // Ctrl/Cmd + +/- - font size
-      if ((e.ctrlKey || e.metaKey) && (e.key === '=' || e.key === '+')) {
-        e.preventDefault();
-        this.increaseFontSize();
-      }
-      if ((e.ctrlKey || e.metaKey) && e.key === '-') {
-        e.preventDefault();
-        this.decreaseFontSize();
-      }
-
-      // Ctrl/Cmd + Shift + V - toggle voice input
-      if ((e.ctrlKey || e.metaKey) && e.shiftKey && e.key === 'V') {
-        e.preventDefault();
-        VoiceInput.toggle();
+      // Match against shortcut table
+      for (const s of SHORTCUTS) {
+        const keyMatch = e.key === s.key || (s.altKey && e.key === s.altKey);
+        const ctrlMatch = s.ctrl ? (e.ctrlKey || e.metaKey) : true;
+        const shiftMatch = s.shift ? e.shiftKey : !e.shiftKey;
+        if (keyMatch && ctrlMatch && shiftMatch) {
+          e.preventDefault();
+          s.action();
+          return;
+        }
       }
     }, true); // Use capture phase to handle before terminal
 
@@ -682,10 +671,7 @@ class CodemanApp {
     }
 
     // Clear any pending reconnect timeout to prevent duplicate connections
-    if (this.sseReconnectTimeout) {
-      clearTimeout(this.sseReconnectTimeout);
-      this.sseReconnectTimeout = null;
-    }
+    this._clearTimer('sseReconnectTimeout');
 
     // Clean up existing SSE listeners before creating new connection (prevents listener accumulation)
     if (this._sseListenerCleanup) {
@@ -742,9 +728,7 @@ class CodemanApp {
         this.eventSource = null;
       }
       // Clear any existing reconnect timeout before setting new one (prevents orphaned timeouts)
-      if (this.sseReconnectTimeout) {
-        clearTimeout(this.sseReconnectTimeout);
-      }
+      this._clearTimer('sseReconnectTimeout');
       // Exponential backoff: 200ms, 500ms, 1s, 2s, 4s, ... up to 30s
       // Fast first retry (200ms) for server-restart case (COM deploy),
       // then ramp up for real network issues.
@@ -955,15 +939,7 @@ class CodemanApp {
     if (data.id === this.activeSessionId) {
       this.terminal.writeln(`\x1b[1;31m Error: ${data.error}\x1b[0m`);
     }
-    const session = this.sessions.get(data.id);
-    this.notificationManager?.notify({
-      urgency: 'critical',
-      category: 'session-error',
-      sessionId: data.id,
-      sessionName: session?.name || this.getShortId(data.id),
-      title: 'Session Error',
-      message: data.error || 'Unknown error',
-    });
+    this._notifySession(data.id, 'critical', 'session-error', 'Session Error', data.error || 'Unknown error');
   }
 
   _onSessionExit(data) {
@@ -976,14 +952,7 @@ class CodemanApp {
     }
     // Notify on unexpected exit (non-zero code)
     if (data.code && data.code !== 0) {
-      this.notificationManager?.notify({
-        urgency: 'critical',
-        category: 'session-crash',
-        sessionId: data.id,
-        sessionName: session?.name || this.getShortId(data.id),
-        title: 'Session Crashed',
-        message: `Exited with code ${data.code}`,
-      });
+      this._notifySession(data.id, 'critical', 'session-crash', 'Session Crashed', `Exited with code ${data.code}`);
     }
   }
 
@@ -1000,15 +969,7 @@ class CodemanApp {
       const threshold = this.notificationManager?.preferences?.stuckThresholdMs || 600000;
       clearTimeout(this.idleTimers.get(data.id));
       this.idleTimers.set(data.id, setTimeout(() => {
-        const s = this.sessions.get(data.id);
-        this.notificationManager?.notify({
-          urgency: 'warning',
-          category: 'session-stuck',
-          sessionId: data.id,
-          sessionName: s?.name || this.getShortId(data.id),
-          title: 'Session Idle',
-          message: `Idle for ${Math.round(threshold / 60000)}+ minutes`,
-        });
+        this._notifySession(data.id, 'warning', 'session-stuck', 'Session Idle', `Idle for ${Math.round(threshold / 60000)}+ minutes`);
         this.idleTimers.delete(data.id);
       }, threshold));
     }
@@ -1039,15 +1000,7 @@ class CodemanApp {
       this.showToast(`Auto-cleared at ${data.tokens.toLocaleString()} tokens`, 'info');
       this.updateRespawnTokens(0);
     }
-    const session = this.sessions.get(data.sessionId);
-    this.notificationManager?.notify({
-      urgency: 'info',
-      category: 'auto-clear',
-      sessionId: data.sessionId,
-      sessionName: session?.name || this.getShortId(data.sessionId),
-      title: 'Auto-Cleared',
-      message: `Context reset at ${(data.tokens || 0).toLocaleString()} tokens`,
-    });
+    this._notifySession(data.sessionId, 'info', 'auto-clear', 'Auto-Cleared', `Context reset at ${(data.tokens || 0).toLocaleString()} tokens`);
   }
 
   _onSessionCliInfo(data) {
@@ -1168,10 +1121,7 @@ class CodemanApp {
 
   /** Close the active WebSocket connection (if any). */
   _disconnectWs() {
-    if (this._wsReconnectTimer) {
-      clearTimeout(this._wsReconnectTimer);
-      this._wsReconnectTimer = null;
-    }
+    this._clearTimer('_wsReconnectTimer');
     this._wsReconnectAttempts = 0;
     if (this._ws) {
       this._ws.onclose = null; // Prevent re-entrant cleanup
@@ -1317,35 +1267,12 @@ class CodemanApp {
     if (!showCjk) window.cjkActive = false;
   }
 
-  handleInit(data) {
-    // Clear the init fallback timer since we got data
-    if (this._initFallbackTimer) {
-      clearTimeout(this._initFallbackTimer);
-      this._initFallbackTimer = null;
-    }
-    const gen = ++this._initGeneration;
-
-    // CJK input form: controlled by user setting (with server env as override)
-    this._serverCjkOverride = data.inputCjkForm || false;
-    this._updateCjkInputState();
-
-    // Update version displays (header and toolbar)
-    if (data.version) {
-      const versionEl = this.$('versionDisplay');
-      const headerVersionEl = this.$('headerVersion');
-      if (versionEl) {
-        versionEl.textContent = `v${data.version}`;
-        versionEl.title = `Codeman v${data.version}`;
-      }
-      if (headerVersionEl) {
-        headerVersionEl.textContent = `v${data.version}`;
-        headerVersionEl.title = `Codeman v${data.version}`;
-      }
-    }
-
-    // Stop any active voice recording on reconnect
-    VoiceInput.cleanup();
-
+  /**
+   * Reset all app state maps, timers, and handlers to a clean baseline.
+   * Called by handleInit() on SSE reconnect / page reload to prevent
+   * memory leaks and stale data.
+   */
+  _resetAllAppState() {
     this.sessions.clear();
     this.ralphStates.clear();
     this.terminalBuffers.clear();
@@ -1359,17 +1286,11 @@ class CodemanApp {
     }
     this.idleTimers.clear();
     // Clear flicker filter state
-    if (this.flickerFilterTimeout) {
-      clearTimeout(this.flickerFilterTimeout);
-      this.flickerFilterTimeout = null;
-    }
+    this._clearTimer('flickerFilterTimeout');
     this.flickerFilterBuffer = '';
     this.flickerFilterActive = false;
     // Clear pending terminal writes
-    if (this.syncWaitTimeout) {
-      clearTimeout(this.syncWaitTimeout);
-      this.syncWaitTimeout = null;
-    }
+    this._clearTimer('syncWaitTimeout');
     this.pendingWrites = [];
     this.writeFrameScheduled = false;
     this._isLoadingBuffer = false;
@@ -1428,6 +1349,36 @@ class CodemanApp {
       clearInterval(this.runSummaryAutoRefreshTimer);
       this.runSummaryAutoRefreshTimer = null;
     }
+  }
+
+  handleInit(data) {
+    // Clear the init fallback timer since we got data
+    this._clearTimer('_initFallbackTimer');
+    const gen = ++this._initGeneration;
+
+    // CJK input form: controlled by user setting (with server env as override)
+    this._serverCjkOverride = data.inputCjkForm || false;
+    this._updateCjkInputState();
+
+    // Update version displays (header and toolbar)
+    if (data.version) {
+      const versionEl = this.$('versionDisplay');
+      const headerVersionEl = this.$('headerVersion');
+      if (versionEl) {
+        versionEl.textContent = `v${data.version}`;
+        versionEl.title = `Codeman v${data.version}`;
+      }
+      if (headerVersionEl) {
+        headerVersionEl.textContent = `v${data.version}`;
+        headerVersionEl.title = `Codeman v${data.version}`;
+      }
+    }
+
+    // Stop any active voice recording on reconnect
+    VoiceInput.cleanup();
+
+    this._resetAllAppState();
+
     data.sessions.forEach(s => {
       this.sessions.set(s.id, s);
       // Load ralph state from session data (only if not explicitly closed by user)
@@ -2001,23 +1952,25 @@ class CodemanApp {
     return this.getShortId(session.id);
   }
 
-  async selectSession(sessionId) {
-    if (this.activeSessionId === sessionId) return;
-    // Focus terminal SYNCHRONOUSLY before any await — iOS Safari only honors
-    // programmatic focus() within the user-gesture call stack (e.g. tab click).
-    // After the first await the gesture context is lost and focus() is silently
-    // ignored, leaving the keyboard unable to send input to the terminal.
-    if (this.terminal) this.terminal.focus();
-
-    const _selStart = performance.now();
-    const _selName = this.sessions.get(sessionId)?.name || sessionId.slice(0,8);
-    _crashDiag.log(`SELECT: ${_selName}`);
-    console.log(`[CRASH-DIAG] selectSession START: ${sessionId.slice(0,8)}`);
-
-    const selectGen = ++this._selectGeneration;
-
-    if (selectGen !== this._selectGeneration) return; // newer tab switch won
+  _notifySession(sessionId, urgency, category, title, message) {
+    const session = this.sessions.get(sessionId);
+    this.notificationManager?.notify({
+      urgency,
+      category,
+      sessionId,
+      sessionName: session?.name || this.getShortId(sessionId),
+      title,
+      message,
+    });
+  }
 
+  /**
+   * Clean up state from the previous session before switching tabs.
+   * Handles: WebSocket teardown, CJK clear, flicker filter, tab completion,
+   * terminal write queue, IME composition, and local echo flush.
+   * @param {string} newSessionId - The session being switched TO.
+   */
+  _cleanupPreviousSession(newSessionId) {
     // Close WebSocket for previous session (new one opens after buffer load)
     this._disconnectWs();
 
@@ -2026,10 +1979,7 @@ class CodemanApp {
     if (cjkEl) cjkEl.value = '';
 
     // Clean up flicker filter state when switching sessions
-    if (this.flickerFilterTimeout) {
-      clearTimeout(this.flickerFilterTimeout);
-      this.flickerFilterTimeout = null;
-    }
+    this._clearTimer('flickerFilterTimeout');
     this.flickerFilterBuffer = '';
     this.flickerFilterActive = false;
 
@@ -2037,14 +1987,11 @@ class CodemanApp {
     this._tabCompletionSessionId = null;
     this._tabCompletionRetries = 0;
     this._tabCompletionBaseText = null;
-    if (this._tabCompletionFallback) { clearTimeout(this._tabCompletionFallback); this._tabCompletionFallback = null; }
-    if (this._clientDropRecoveryTimer) { clearTimeout(this._clientDropRecoveryTimer); this._clientDropRecoveryTimer = null; }
+    this._clearTimer('_tabCompletionFallback');
+    this._clearTimer('_clientDropRecoveryTimer');
 
     // Clean up pending terminal writes to prevent old session data from appearing in new session
-    if (this.syncWaitTimeout) {
-      clearTimeout(this.syncWaitTimeout);
-      this.syncWaitTimeout = null;
-    }
+    this._clearTimer('syncWaitTimeout');
     this.pendingWrites = [];
     this.writeFrameScheduled = false;
     this._isLoadingBuffer = false;
@@ -2094,9 +2041,29 @@ class CodemanApp {
     // Only sessions with prior flushed text (from tab-switch-away) need detection.
     // After the user's first Enter, clear() resets _bufferDetectDone = false,
     // re-enabling detection for tab completion and other legitimate cases.
-    if (this._localEchoOverlay && !this._flushedOffsets?.has(sessionId)) {
+    if (this._localEchoOverlay && !this._flushedOffsets?.has(newSessionId)) {
       this._localEchoOverlay.suppressBufferDetection();
     }
+  }
+
+  async selectSession(sessionId) {
+    if (this.activeSessionId === sessionId) return;
+    // Focus terminal SYNCHRONOUSLY before any await — iOS Safari only honors
+    // programmatic focus() within the user-gesture call stack (e.g. tab click).
+    // After the first await the gesture context is lost and focus() is silently
+    // ignored, leaving the keyboard unable to send input to the terminal.
+    if (this.terminal) this.terminal.focus();
+
+    const _selStart = performance.now();
+    const _selName = this.sessions.get(sessionId)?.name || sessionId.slice(0,8);
+    _crashDiag.log(`SELECT: ${_selName}`);
+    console.log(`[CRASH-DIAG] selectSession START: ${sessionId.slice(0,8)}`);
+
+    const selectGen = ++this._selectGeneration;
+
+    if (selectGen !== this._selectGeneration) return; // newer tab switch won
+
+    this._cleanupPreviousSession(sessionId);
     this.activeSessionId = sessionId;
     try { localStorage.setItem('codeman-active-session', sessionId); } catch {}
     this.hideWelcome();
@@ -2186,7 +2153,7 @@ class CodemanApp {
         this.terminal.clear();
         this.terminal.reset();
         await this.chunkedTerminalWrite(cachedBuffer);
-        if (selectGen !== this._selectGeneration) { if (this._isLoadingBuffer) this._finishBufferLoad(); this._restoringFlushedState = false; return; }
+        if (this._isStaleSelect(selectGen)) return;
         this.terminal.scrollToBottom();
         _crashDiag.log('CACHE_DONE');
       } else if (sessionIsBusy) {
@@ -2198,7 +2165,7 @@ class CodemanApp {
 
       _crashDiag.log('FETCH_START');
       const res = await fetch(`/api/sessions/${sessionId}/terminal?tail=${TERMINAL_TAIL_SIZE}`);
-      if (selectGen !== this._selectGeneration) { if (this._isLoadingBuffer) this._finishBufferLoad(); this._restoringFlushedState = false; return; }
+      if (this._isStaleSelect(selectGen)) return;
       const data = await res.json();
       _crashDiag.log(`FETCH_DONE: ${data.terminalBuffer ? (data.terminalBuffer.length/1024).toFixed(0) + 'KB' : 'empty'} truncated=${data.truncated}`);
 
@@ -2217,7 +2184,7 @@ class CodemanApp {
           }
           // Use chunked write for large buffers to avoid UI jank
           await this.chunkedTerminalWrite(data.terminalBuffer);
-          if (selectGen !== this._selectGeneration) { if (this._isLoadingBuffer) this._finishBufferLoad(); this._restoringFlushedState = false; return; }
+          if (this._isStaleSelect(selectGen)) return;
           // Ensure terminal is scrolled to bottom after buffer load
           this.terminal.scrollToBottom();
         }
@@ -2624,9 +2591,7 @@ class CodemanApp {
   updateTokens() {
     // Debounce at 200ms — token display is non-critical and shouldn't
     // compete with input handling on the main thread
-    if (this._updateTokensTimeout) {
-      clearTimeout(this._updateTokensTimeout);
-    }
+    this._clearTimer('_updateTokensTimeout');
     this._updateTokensTimeout = setTimeout(() => {
       this._updateTokensTimeout = null;
       this._updateTokensImmediate();

src/web/public/panels-ui.js

@@ -14,6 +14,13 @@
  */
 
 Object.assign(CodemanApp.prototype, {
+  _addActivityEntry(agentId, entry, maxSize = 50) {
+    const activity = this.subagentActivity.get(agentId) || [];
+    activity.push(entry);
+    if (activity.length > maxSize) activity.shift();
+    this.subagentActivity.set(agentId, activity);
+  },
+
   // Tasks
   _onTaskCreated(data) {
     this.renderSessionTabs();
@@ -106,15 +113,7 @@ Object.assign(CodemanApp.prototype, {
 
     // Notify about new subagent discovery
     const parentId = this.subagentParentMap.get(data.agentId);
-    const parentSession = parentId ? this.sessions.get(parentId) : null;
-    this.notificationManager?.notify({
-      urgency: 'info',
-      category: 'subagent-spawn',
-      sessionId: parentId || data.sessionId,
-      sessionName: parentSession?.name || parentId || data.sessionId,
-      title: 'Subagent Spawned',
-      message: data.description || 'New background agent started',
-    });
+    this._notifySession(parentId || data.sessionId, 'info', 'subagent-spawn', 'Subagent Spawned', data.description || 'New background agent started');
   },
 
   _onSubagentUpdated(data) {
@@ -135,10 +134,7 @@ Object.assign(CodemanApp.prototype, {
   },
 
   _onSubagentToolCall(data) {
-    const activity = this.subagentActivity.get(data.agentId) || [];
-    activity.push({ type: 'tool', ...data });
-    if (activity.length > 50) activity.shift(); // Keep last 50 entries
-    this.subagentActivity.set(data.agentId, activity);
+    this._addActivityEntry(data.agentId, { type: 'tool', ...data });
     if (this.activeSubagentId === data.agentId) {
       this.renderSubagentDetail();
     }
@@ -150,10 +146,7 @@ Object.assign(CodemanApp.prototype, {
   },
 
   _onSubagentProgress(data) {
-    const activity = this.subagentActivity.get(data.agentId) || [];
-    activity.push({ type: 'progress', ...data });
-    if (activity.length > 50) activity.shift();
-    this.subagentActivity.set(data.agentId, activity);
+    this._addActivityEntry(data.agentId, { type: 'progress', ...data });
     if (this.activeSubagentId === data.agentId) {
       this.renderSubagentDetail();
     }
@@ -164,10 +157,7 @@ Object.assign(CodemanApp.prototype, {
   },
 
   _onSubagentMessage(data) {
-    const activity = this.subagentActivity.get(data.agentId) || [];
-    activity.push({ type: 'message', ...data });
-    if (activity.length > 50) activity.shift();
-    this.subagentActivity.set(data.agentId, activity);
+    this._addActivityEntry(data.agentId, { type: 'message', ...data });
     if (this.activeSubagentId === data.agentId) {
       this.renderSubagentDetail();
     }
@@ -190,10 +180,7 @@ Object.assign(CodemanApp.prototype, {
     }
 
     // Add to activity stream
-    const activity = this.subagentActivity.get(data.agentId) || [];
-    activity.push({ type: 'tool_result', ...data });
-    if (activity.length > 50) activity.shift();
-    this.subagentActivity.set(data.agentId, activity);
+    this._addActivityEntry(data.agentId, { type: 'tool_result', ...data });
 
     if (this.activeSubagentId === data.agentId) {
       this.renderSubagentDetail();
@@ -224,15 +211,7 @@ Object.assign(CodemanApp.prototype, {
 
     // Notify about subagent completion
     const parentId = this.subagentParentMap.get(data.agentId);
-    const parentSession = parentId ? this.sessions.get(parentId) : null;
-    this.notificationManager?.notify({
-      urgency: 'info',
-      category: 'subagent-complete',
-      sessionId: parentId || existing?.sessionId || data.sessionId,
-      sessionName: parentSession?.name || parentId || data.sessionId,
-      title: 'Subagent Completed',
-      message: existing?.description || data.description || 'Background agent finished',
-    });
+    this._notifySession(parentId || existing?.sessionId || data.sessionId, 'info', 'subagent-complete', 'Subagent Completed', existing?.description || data.description || 'Background agent finished');
 
     // Clean up activity/tool data for completed agents after 5 minutes
     // This prevents memory leaks from long-running sessions with many subagents

src/web/public/ralph-panel.js

@@ -45,15 +45,7 @@ Object.assign(CodemanApp.prototype, {
       this.updateRalphState(data.sessionId, existing);
     }
 
-    const session = this.sessions.get(data.sessionId);
-    this.notificationManager?.notify({
-      urgency: 'warning',
-      category: 'ralph-complete',
-      sessionId: data.sessionId,
-      sessionName: session?.name || this.getShortId(data.sessionId),
-      title: 'Loop Complete',
-      message: `Completion: ${data.phrase || 'unknown'}`,
-    });
+    this._notifySession(data.sessionId, 'warning', 'ralph-complete', 'Loop Complete', `Completion: ${data.phrase || 'unknown'}`);
   },
 
   _onRalphStatusUpdate(data) {
@@ -68,28 +60,12 @@ Object.assign(CodemanApp.prototype, {
     this.updateRalphState(data.sessionId, { circuitBreaker: data.status });
     // Notify if circuit breaker opens
     if (data.status.state === 'OPEN') {
-      const session = this.sessions.get(data.sessionId);
-      this.notificationManager?.notify({
-        urgency: 'critical',
-        category: 'circuit-breaker',
-        sessionId: data.sessionId,
-        sessionName: session?.name || this.getShortId(data.sessionId),
-        title: 'Circuit Breaker Open',
-        message: data.status.reason || 'Loop stuck - no progress detected',
-      });
+      this._notifySession(data.sessionId, 'critical', 'circuit-breaker', 'Circuit Breaker Open', data.status.reason || 'Loop stuck - no progress detected');
     }
   },
 
   _onExitGateMet(data) {
-    const session = this.sessions.get(data.sessionId);
-    this.notificationManager?.notify({
-      urgency: 'warning',
-      category: 'exit-gate',
-      sessionId: data.sessionId,
-      sessionName: session?.name || this.getShortId(data.sessionId),
-      title: 'Exit Gate Met',
-      message: `Loop ready to exit (indicators: ${data.completionIndicators})`,
-    });
+    this._notifySession(data.sessionId, 'warning', 'exit-gate', 'Exit Gate Met', `Loop ready to exit (indicators: ${data.completionIndicators})`);
   },
 
   // Bash tools

src/web/public/respawn-ui.js

@@ -44,21 +44,13 @@ Object.assign(CodemanApp.prototype, {
   },
 
   _onRespawnBlocked(data) {
-    const session = this.sessions.get(data.sessionId);
     const reasonMap = {
       circuit_breaker_open: 'Circuit Breaker Open',
       exit_signal: 'Exit Signal Detected',
       status_blocked: 'Claude Reported BLOCKED',
     };
     const title = reasonMap[data.reason] || 'Respawn Blocked';
-    this.notificationManager?.notify({
-      urgency: 'critical',
-      category: 'respawn-blocked',
-      sessionId: data.sessionId,
-      sessionName: session?.name || this.getShortId(data.sessionId),
-      title,
-      message: data.details,
-    });
+    this._notifySession(data.sessionId, 'critical', 'respawn-blocked', title, data.details);
     // Update respawn panel to show blocked state
     if (data.sessionId === this.activeSessionId) {
       const stateEl = document.getElementById('respawnStateLabel');
@@ -71,14 +63,7 @@ Object.assign(CodemanApp.prototype, {
 
   _onRespawnAutoAcceptSent(data) {
     const session = this.sessions.get(data.sessionId);
-    this.notificationManager?.notify({
-      urgency: 'info',
-      category: 'auto-accept',
-      sessionId: data.sessionId,
-      sessionName: session?.name || this.getShortId(data.sessionId),
-      title: 'Plan Accepted',
-      message: `Accepted plan mode for ${session?.name || 'session'}`,
-    });
+    this._notifySession(data.sessionId, 'info', 'auto-accept', 'Plan Accepted', `Accepted plan mode for ${session?.name || 'session'}`);
   },
 
   _onRespawnDetectionUpdate(data) {
@@ -144,15 +129,7 @@ Object.assign(CodemanApp.prototype, {
   },
 
   _onRespawnError(data) {
-    const session = this.sessions.get(data.sessionId);
-    this.notificationManager?.notify({
-      urgency: 'critical',
-      category: 'session-error',
-      sessionId: data.sessionId,
-      sessionName: session?.name || data.sessionId,
-      title: 'Respawn Error',
-      message: data.error || data.message || 'Respawn encountered an error',
-    });
+    this._notifySession(data.sessionId, 'critical', 'session-error', 'Respawn Error', data.error || data.message || 'Respawn encountered an error');
   },
 
   _onRespawnActionLog(data) {

src/web/public/session-ui.js

@@ -109,16 +109,10 @@ Object.assign(CodemanApp.prototype, {
 
   async saveLastUsedCase(caseName) {
     try {
-      // Get current settings
-      const res = await fetch('/api/settings');
-      const settings = res.ok ? await res.json() : {};
-      // Update lastUsedCase
-      settings.lastUsedCase = caseName;
-      // Save back
       await fetch('/api/settings', {
         method: 'PUT',
         headers: { 'Content-Type': 'application/json' },
-        body: JSON.stringify(settings)
+        body: JSON.stringify({ lastUsedCase: caseName })
       });
     } catch (err) {
       console.error('Failed to save last used case:', err);

src/web/public/settings-ui.js

@@ -14,92 +14,46 @@
 Object.assign(CodemanApp.prototype, {
   // Hooks (Claude Code hook events)
   _onHookIdlePrompt(data) {
-    const session = this.sessions.get(data.sessionId);
     // Always track pending hook - alert will show when switching away from session
     if (data.sessionId) {
       this.setPendingHook(data.sessionId, 'idle_prompt');
     }
-    this.notificationManager?.notify({
-      urgency: 'warning',
-      category: 'hook-idle',
-      sessionId: data.sessionId,
-      sessionName: session?.name || data.sessionId,
-      title: 'Waiting for Input',
-      message: data.message || 'Claude is idle and waiting for a prompt',
-    });
+    this._notifySession(data.sessionId, 'warning', 'hook-idle', 'Waiting for Input', data.message || 'Claude is idle and waiting for a prompt');
   },
 
   _onHookPermissionPrompt(data) {
-    const session = this.sessions.get(data.sessionId);
     // Always track pending hook - action alerts need user interaction to clear
     if (data.sessionId) {
       this.setPendingHook(data.sessionId, 'permission_prompt');
     }
     const toolInfo = data.tool ? `${data.tool}${data.command ? ': ' + data.command : data.file ? ': ' + data.file : ''}` : '';
-    this.notificationManager?.notify({
-      urgency: 'critical',
-      category: 'hook-permission',
-      sessionId: data.sessionId,
-      sessionName: session?.name || data.sessionId,
-      title: 'Permission Required',
-      message: toolInfo || 'Claude needs tool approval to continue',
-    });
+    this._notifySession(data.sessionId, 'critical', 'hook-permission', 'Permission Required', toolInfo || 'Claude needs tool approval to continue');
   },
 
   _onHookElicitationDialog(data) {
-    const session = this.sessions.get(data.sessionId);
     // Always track pending hook - action alerts need user interaction to clear
     if (data.sessionId) {
       this.setPendingHook(data.sessionId, 'elicitation_dialog');
     }
-    this.notificationManager?.notify({
-      urgency: 'critical',
-      category: 'hook-elicitation',
-      sessionId: data.sessionId,
-      sessionName: session?.name || data.sessionId,
-      title: 'Question Asked',
-      message: data.question || 'Claude is asking a question and waiting for your answer',
-    });
+    this._notifySession(data.sessionId, 'critical', 'hook-elicitation', 'Question Asked', data.question || 'Claude is asking a question and waiting for your answer');
   },
 
   _onHookStop(data) {
-    const session = this.sessions.get(data.sessionId);
     // Clear all pending hooks when Claude finishes responding
     if (data.sessionId) {
       this.clearPendingHooks(data.sessionId);
     }
-    this.notificationManager?.notify({
-      urgency: 'info',
-      category: 'hook-stop',
-      sessionId: data.sessionId,
-      sessionName: session?.name || data.sessionId,
-      title: 'Response Complete',
-      message: data.reason || 'Claude has finished responding',
-    });
+    this._notifySession(data.sessionId, 'info', 'hook-stop', 'Response Complete', data.reason || 'Claude has finished responding');
   },
 
   _onHookTeammateIdle(data) {
     const session = this.sessions.get(data.sessionId);
-    this.notificationManager?.notify({
-      urgency: 'warning',
-      category: 'hook-teammate-idle',
-      sessionId: data.sessionId,
-      sessionName: session?.name || data.sessionId,
-      title: 'Teammate Idle',
-      message: `A teammate is idle in ${session?.name || data.sessionId}`,
-    });
+    this._notifySession(data.sessionId, 'warning', 'hook-teammate-idle', 'Teammate Idle', `A teammate is idle in ${session?.name || data.sessionId}`);
   },
 
   _onHookTaskCompleted(data) {
     const session = this.sessions.get(data.sessionId);
-    this.notificationManager?.notify({
-      urgency: 'info',
-      category: 'hook-task-completed',
-      sessionId: data.sessionId,
-      sessionName: session?.name || data.sessionId,
-      title: 'Task Completed',
-      message: `A team task completed in ${session?.name || data.sessionId}`,
-    });
+    this._notifySession(data.sessionId, 'info', 'hook-task-completed', 'Task Completed', `A team task completed in ${session?.name || data.sessionId}`);
   },
 
 
@@ -517,16 +471,17 @@ Object.assign(CodemanApp.prototype, {
     }
   },
 
-  _updateTunnelUrlDisplay(url) {
-    const row = document.getElementById('tunnelUrlRow');
-    const display = document.getElementById('tunnelUrlDisplay');
+  _updateTunnelUrlRow(rowId, displayId, url, suffix = '') {
+    const row = document.getElementById(rowId);
+    const display = document.getElementById(displayId);
     if (!row || !display) return;
     if (url) {
+      const fullUrl = url + suffix;
       row.style.display = '';
-      display.textContent = url;
+      display.textContent = fullUrl;
       display.onclick = () => {
-        navigator.clipboard.writeText(url).then(() => {
-          this.showToast('Tunnel URL copied', 'success');
+        navigator.clipboard.writeText(fullUrl).then(() => {
+          this.showToast(`${suffix ? 'Upload' : 'Tunnel'} URL copied`, 'success');
         });
       };
     } else {
@@ -534,24 +489,11 @@ Object.assign(CodemanApp.prototype, {
       display.textContent = '';
       display.onclick = null;
     }
-    // Upload URL row
-    const uploadRow = document.getElementById('tunnelUploadUrlRow');
-    const uploadDisplay = document.getElementById('tunnelUploadUrlDisplay');
-    if (!uploadRow || !uploadDisplay) return;
-    if (url) {
-      const uploadUrl = url + '/upload.html';
-      uploadRow.style.display = '';
-      uploadDisplay.textContent = uploadUrl;
-      uploadDisplay.onclick = () => {
-        navigator.clipboard.writeText(uploadUrl).then(() => {
-          this.showToast('Upload URL copied', 'success');
-        });
-      };
-    } else {
-      uploadRow.style.display = 'none';
-      uploadDisplay.textContent = '';
-      uploadDisplay.onclick = null;
-    }
+  },
+
+  _updateTunnelUrlDisplay(url) {
+    this._updateTunnelUrlRow('tunnelUrlRow', 'tunnelUrlDisplay', url);
+    this._updateTunnelUrlRow('tunnelUploadUrlRow', 'tunnelUploadUrlDisplay', url, '/upload.html');
   },
 
   showTunnelQR() {

src/web/respawn-event-wiring.ts

@@ -0,0 +1,360 @@
+/**
+ * @fileoverview Respawn event wiring — pure functions that connect RespawnController
+ * events to SSE broadcasts, push notifications, and run summary tracking.
+ *
+ * Extracted from WebServer to keep respawn-specific event plumbing separate from
+ * HTTP/session concerns. Follows the same DI pattern as session-listener-wiring.ts.
+ */
+
+import { Session } from '../session.js';
+import { RespawnController, RespawnConfig, RespawnState } from '../respawn-controller.js';
+import type { PersistedRespawnConfig } from '../types.js';
+import type { RunSummaryTracker } from '../run-summary.js';
+import type { TerminalMultiplexer } from '../mux-interface.js';
+import type { TeamWatcher } from '../team-watcher.js';
+import { SseEvent } from './sse-events.js';
+
+// ============================================================================
+// Dependency Interface
+// ============================================================================
+
+export interface RespawnWiringDeps {
+  broadcast(event: string, data: unknown): void;
+  sendPushNotifications(event: string, data: Record<string, unknown>): void;
+  persistSessionState(session: Session): void;
+  getSession(sessionId: string): Session | undefined;
+  sessionExists(sessionId: string): boolean;
+  getRunSummaryTracker(sessionId: string): RunSummaryTracker | undefined;
+  getRespawnControllers(): Map<string, RespawnController>;
+  getRespawnTimers(): Map<string, { timer: NodeJS.Timeout; endAt: number; startedAt: number }>;
+  getPendingRespawnStarts(): Map<string, NodeJS.Timeout>;
+  teamWatcher: TeamWatcher;
+  serverStartTime: number;
+  respawnRestoreGracePeriodMs: number;
+  mux: TerminalMultiplexer;
+}
+
+// ============================================================================
+// Respawn Listener Wiring
+// ============================================================================
+
+/**
+ * Wire a RespawnController's events to SSE broadcasts, push notifications,
+ * and run summary tracking.
+ */
+export function wireRespawnListeners(sessionId: string, controller: RespawnController, deps: RespawnWiringDeps): void {
+  // Wire team watcher for team-aware idle detection
+  controller.setTeamWatcher(deps.teamWatcher);
+
+  // Helper to get tracker lazily (may not exist at setup time for restored sessions)
+  const getTracker = () => deps.getRunSummaryTracker(sessionId);
+
+  // ─── Respawn State Machine ──────────────────────────────
+
+  /** Broadcasts `respawn:stateChanged` — state machine transition (e.g., IDLE → DETECTING → RESPAWNING) */
+  controller.on('stateChanged', (state: RespawnState, prevState: RespawnState) => {
+    deps.broadcast(SseEvent.RespawnStateChanged, { sessionId, state, prevState });
+    const tracker = getTracker();
+    if (tracker) tracker.recordStateChange(state, `${prevState} → ${state}`);
+  });
+
+  // ─── Respawn Cycle Lifecycle ────────────────────────────
+
+  /** Broadcasts `respawn:cycleStarted` — new respawn cycle begins */
+  controller.on('respawnCycleStarted', (cycleNumber: number) => {
+    deps.broadcast(SseEvent.RespawnCycleStarted, { sessionId, cycleNumber });
+  });
+
+  /** Broadcasts `respawn:cycleCompleted` — respawn cycle finished */
+  controller.on('respawnCycleCompleted', (cycleNumber: number) => {
+    deps.broadcast(SseEvent.RespawnCycleCompleted, { sessionId, cycleNumber });
+  });
+
+  /** Broadcasts `respawn:blocked` + push notification — respawn blocked by error/circuit breaker */
+  controller.on('respawnBlocked', (data: { reason: string; details: string }) => {
+    deps.broadcast(SseEvent.RespawnBlocked, { sessionId, reason: data.reason, details: data.details });
+    const sessionForPush = deps.getSession(sessionId);
+    deps.sendPushNotifications(SseEvent.RespawnBlocked, {
+      sessionId,
+      sessionName: sessionForPush?.name ?? sessionId.slice(0, 8),
+      reason: data.reason,
+    });
+    const tracker = getTracker();
+    if (tracker) tracker.recordWarning(`Respawn blocked: ${data.reason}`, data.details);
+  });
+
+  // ─── Respawn Step Progress ──────────────────────────────
+
+  /** Broadcasts `respawn:stepSent` — respawn step input sent (e.g., /clear, kickstart prompt) */
+  controller.on('stepSent', (step: string, input: string) => {
+    deps.broadcast(SseEvent.RespawnStepSent, { sessionId, step, input });
+  });
+
+  /** Broadcasts `respawn:stepCompleted` — respawn step finished */
+  controller.on('stepCompleted', (step: string) => {
+    deps.broadcast(SseEvent.RespawnStepCompleted, { sessionId, step });
+  });
+
+  /** Broadcasts `respawn:detectionUpdate` — idle/completion detection state changed */
+  controller.on('detectionUpdate', (detection: unknown) => {
+    deps.broadcast(SseEvent.RespawnDetectionUpdate, { sessionId, detection });
+  });
+
+  /** Broadcasts `respawn:autoAcceptSent` — auto-accepted a permission prompt */
+  controller.on('autoAcceptSent', () => {
+    deps.broadcast(SseEvent.RespawnAutoAcceptSent, { sessionId });
+  });
+
+  // ─── AI Checker Events ──────────────────────────────────
+
+  /** Broadcasts `respawn:aiCheckStarted` — AI idle checker invoked */
+  controller.on('aiCheckStarted', () => {
+    deps.broadcast(SseEvent.RespawnAiCheckStarted, { sessionId });
+  });
+
+  /** Broadcasts `respawn:aiCheckCompleted` — AI idle check returned verdict (idle/working/stuck) */
+  controller.on('aiCheckCompleted', (result: { verdict: string; reasoning: string; durationMs: number }) => {
+    deps.broadcast(SseEvent.RespawnAiCheckCompleted, {
+      sessionId,
+      verdict: result.verdict,
+      reasoning: result.reasoning,
+      durationMs: result.durationMs,
+    });
+    const tracker = getTracker();
+    if (tracker) tracker.recordAiCheckResult(result.verdict);
+  });
+
+  /** Broadcasts `respawn:aiCheckFailed` — AI idle check errored */
+  controller.on('aiCheckFailed', (error: string) => {
+    deps.broadcast(SseEvent.RespawnAiCheckFailed, { sessionId, error });
+    const tracker = getTracker();
+    if (tracker) tracker.recordError('AI check failed', error);
+  });
+
+  /** Broadcasts `respawn:aiCheckCooldown` — AI check on cooldown after failure */
+  controller.on('aiCheckCooldown', (active: boolean, endsAt: number | null) => {
+    deps.broadcast(SseEvent.RespawnAiCheckCooldown, { sessionId, active, endsAt });
+  });
+
+  // ─── Plan Checker Events ────────────────────────────────
+
+  /** Broadcasts `respawn:planCheckStarted` — AI plan completion checker invoked */
+  controller.on('planCheckStarted', () => {
+    deps.broadcast(SseEvent.RespawnPlanCheckStarted, { sessionId });
+  });
+
+  /** Broadcasts `respawn:planCheckCompleted` — plan check returned verdict */
+  controller.on('planCheckCompleted', (result: { verdict: string; reasoning: string; durationMs: number }) => {
+    deps.broadcast(SseEvent.RespawnPlanCheckCompleted, {
+      sessionId,
+      verdict: result.verdict,
+      reasoning: result.reasoning,
+      durationMs: result.durationMs,
+    });
+  });
+
+  /** Broadcasts `respawn:planCheckFailed` — plan check errored */
+  controller.on('planCheckFailed', (error: string) => {
+    deps.broadcast(SseEvent.RespawnPlanCheckFailed, { sessionId, error });
+  });
+
+  // ─── Timer Events (UI countdown display) ────────────────
+
+  /** Broadcasts `respawn:timerStarted` — countdown timer started (idle, cooldown, etc.) */
+  controller.on('timerStarted', (timer) => {
+    deps.broadcast(SseEvent.RespawnTimerStarted, { sessionId, timer });
+  });
+
+  /** Broadcasts `respawn:timerCancelled` — timer cancelled before expiry */
+  controller.on('timerCancelled', (timerName, reason) => {
+    deps.broadcast(SseEvent.RespawnTimerCancelled, { sessionId, timerName, reason });
+  });
+
+  /** Broadcasts `respawn:timerCompleted` — timer expired */
+  controller.on('timerCompleted', (timerName) => {
+    deps.broadcast(SseEvent.RespawnTimerCompleted, { sessionId, timerName });
+  });
+
+  // ─── Logging & Errors ───────────────────────────────────
+
+  /** Broadcasts `respawn:actionLog` — respawn action logged for audit/debugging */
+  controller.on('actionLog', (action) => {
+    deps.broadcast(SseEvent.RespawnActionLog, { sessionId, action });
+  });
+
+  /** Broadcasts `respawn:log` — general respawn log message */
+  controller.on('log', (message: string) => {
+    deps.broadcast(SseEvent.RespawnLog, { sessionId, message });
+  });
+
+  /** Broadcasts `respawn:error` — respawn controller error */
+  controller.on('error', (error: Error) => {
+    deps.broadcast(SseEvent.RespawnError, { sessionId, error: error.message });
+    const tracker = getTracker();
+    if (tracker) tracker.recordError('Respawn error', error.message);
+  });
+}
+
+// ============================================================================
+// Timed Respawn
+// ============================================================================
+
+/**
+ * Set up a duration-limited respawn timer that stops respawn after N minutes.
+ */
+export function setupTimedRespawn(sessionId: string, durationMinutes: number, deps: RespawnWiringDeps): void {
+  const timers = deps.getRespawnTimers();
+
+  // Clear existing timer if any
+  const existing = timers.get(sessionId);
+  if (existing) {
+    clearTimeout(existing.timer);
+  }
+
+  const now = Date.now();
+  const endAt = now + durationMinutes * 60 * 1000;
+
+  const timer = setTimeout(
+    () => {
+      // Stop respawn when time is up
+      const controllers = deps.getRespawnControllers();
+      const controller = controllers.get(sessionId);
+      if (controller) {
+        controller.stop();
+        controller.removeAllListeners();
+        controllers.delete(sessionId);
+        deps.broadcast(SseEvent.RespawnStopped, { sessionId, reason: 'duration_expired' });
+      }
+      timers.delete(sessionId);
+      // Update persisted state (respawn no longer active)
+      const session = deps.getSession(sessionId);
+      if (session) {
+        deps.persistSessionState(session);
+      }
+    },
+    durationMinutes * 60 * 1000
+  );
+
+  timers.set(sessionId, { timer, endAt, startedAt: now });
+  deps.broadcast(SseEvent.RespawnTimerStarted, { sessionId, durationMinutes, endAt, startedAt: now });
+}
+
+// ============================================================================
+// Respawn Controller Restore
+// ============================================================================
+
+/**
+ * Restore a RespawnController from persisted configuration.
+ * Creates the controller, wires listeners, and starts after a grace period.
+ */
+export function restoreRespawnController(
+  session: Session,
+  config: PersistedRespawnConfig,
+  source: string,
+  deps: RespawnWiringDeps
+): void {
+  const controller = new RespawnController(session, {
+    idleTimeoutMs: config.idleTimeoutMs,
+    updatePrompt: config.updatePrompt,
+    interStepDelayMs: config.interStepDelayMs,
+    enabled: true,
+    sendClear: config.sendClear,
+    sendInit: config.sendInit,
+    kickstartPrompt: config.kickstartPrompt,
+    completionConfirmMs: config.completionConfirmMs,
+    noOutputTimeoutMs: config.noOutputTimeoutMs,
+    autoAcceptPrompts: config.autoAcceptPrompts,
+    autoAcceptDelayMs: config.autoAcceptDelayMs,
+    aiIdleCheckEnabled: config.aiIdleCheckEnabled,
+    aiIdleCheckModel: config.aiIdleCheckModel,
+    aiIdleCheckMaxContext: config.aiIdleCheckMaxContext,
+    aiIdleCheckTimeoutMs: config.aiIdleCheckTimeoutMs,
+    aiIdleCheckCooldownMs: config.aiIdleCheckCooldownMs,
+    aiPlanCheckEnabled: config.aiPlanCheckEnabled,
+    aiPlanCheckModel: config.aiPlanCheckModel,
+    aiPlanCheckMaxContext: config.aiPlanCheckMaxContext,
+    aiPlanCheckTimeoutMs: config.aiPlanCheckTimeoutMs,
+    aiPlanCheckCooldownMs: config.aiPlanCheckCooldownMs,
+  });
+
+  const controllers = deps.getRespawnControllers();
+  controllers.set(session.id, controller);
+  wireRespawnListeners(session.id, controller, deps);
+
+  // Calculate delay: wait until grace period after server start before starting respawn
+  // This prevents false idle detection immediately after a server restart/rebuild
+  const timeSinceStart = Date.now() - deps.serverStartTime;
+  const delayMs = Math.max(0, deps.respawnRestoreGracePeriodMs - timeSinceStart);
+
+  const pendingStarts = deps.getPendingRespawnStarts();
+
+  if (delayMs > 0) {
+    console.log(
+      `[Server] Restored respawn controller for session ${session.id} from ${source} (will start in ${Math.ceil(delayMs / 1000)}s)`
+    );
+    const delayTimer = setTimeout(() => {
+      pendingStarts.delete(session.id);
+      // Verify session still exists (may have been deleted during grace period)
+      if (!deps.sessionExists(session.id)) {
+        console.log(`[Server] Skipping restored respawn start - session ${session.id} no longer exists`);
+        return;
+      }
+      // Double-check controller still exists and is stopped
+      const ctrl = controllers.get(session.id);
+      if (ctrl && ctrl.state === 'stopped') {
+        ctrl.start();
+        deps.broadcast(SseEvent.RespawnStarted, { sessionId: session.id });
+        console.log(`[Server] Restored respawn controller started for session ${session.id}`);
+      }
+    }, delayMs);
+    pendingStarts.set(session.id, delayTimer);
+  } else {
+    // Grace period has passed, start immediately
+    controller.start();
+    console.log(`[Server] Restored respawn controller for session ${session.id} from ${source} (started immediately)`);
+  }
+
+  if (config.durationMinutes && config.durationMinutes > 0) {
+    setupTimedRespawn(session.id, config.durationMinutes, deps);
+  }
+}
+
+// ============================================================================
+// Respawn Config Persistence
+// ============================================================================
+
+/**
+ * Save respawn config to mux for restart recovery.
+ */
+export function saveRespawnConfig(
+  sessionId: string,
+  config: RespawnConfig,
+  mux: TerminalMultiplexer,
+  durationMinutes?: number
+): void {
+  const persistedConfig: PersistedRespawnConfig = {
+    enabled: config.enabled,
+    idleTimeoutMs: config.idleTimeoutMs,
+    updatePrompt: config.updatePrompt,
+    interStepDelayMs: config.interStepDelayMs,
+    sendClear: config.sendClear,
+    sendInit: config.sendInit,
+    kickstartPrompt: config.kickstartPrompt,
+    autoAcceptPrompts: config.autoAcceptPrompts,
+    autoAcceptDelayMs: config.autoAcceptDelayMs,
+    completionConfirmMs: config.completionConfirmMs,
+    noOutputTimeoutMs: config.noOutputTimeoutMs,
+    aiIdleCheckEnabled: config.aiIdleCheckEnabled,
+    aiIdleCheckModel: config.aiIdleCheckModel,
+    aiIdleCheckMaxContext: config.aiIdleCheckMaxContext,
+    aiIdleCheckTimeoutMs: config.aiIdleCheckTimeoutMs,
+    aiIdleCheckCooldownMs: config.aiIdleCheckCooldownMs,
+    aiPlanCheckEnabled: config.aiPlanCheckEnabled,
+    aiPlanCheckModel: config.aiPlanCheckModel,
+    aiPlanCheckMaxContext: config.aiPlanCheckMaxContext,
+    aiPlanCheckTimeoutMs: config.aiPlanCheckTimeoutMs,
+    aiPlanCheckCooldownMs: config.aiPlanCheckCooldownMs,
+    durationMinutes,
+  };
+  mux.updateRespawnConfig(sessionId, persistedConfig);
+}

src/web/route-helpers.ts

@@ -6,6 +6,8 @@
  */
 
 import { join, resolve, relative, isAbsolute } from 'node:path';
+import { realpathSync } from 'node:fs';
+import fs from 'node:fs/promises';
 import { homedir } from 'node:os';
 import type { z } from 'zod';
 import { Session } from '../session.js';
@@ -33,6 +35,45 @@ export function validatePathWithinBase(name: string, baseDir: string): string |
   return fullPath;
 }
 
+/**
+ * Reads and parses a JSON config file, returning a default value on ENOENT.
+ * Logs an error for any I/O failure other than a missing file.
+ */
+export async function readJsonConfig<T>(filePath: string, logLabel: string, defaultValue: T): Promise<T> {
+  try {
+    const content = await fs.readFile(filePath, 'utf-8');
+    return JSON.parse(content) as T;
+  } catch (err) {
+    if ((err as NodeJS.ErrnoException).code !== 'ENOENT') {
+      console.error(`Failed to read ${logLabel}:`, err);
+    }
+    return defaultValue;
+  }
+}
+
+/**
+ * Validates that a file path (possibly containing symlinks) resolves to a location
+ * within the given session working directory. Returns the resolved and relative paths,
+ * or null if the path escapes the directory or doesn't exist.
+ */
+export function validateSessionFilePath(
+  sessionWorkingDir: string,
+  filePath: string
+): { resolvedPath: string; relativePath: string } | null {
+  const fullPath = resolve(sessionWorkingDir, filePath);
+  let resolvedPath: string;
+  try {
+    resolvedPath = realpathSync(fullPath);
+  } catch {
+    return null;
+  }
+  const relativePath = relative(sessionWorkingDir, resolvedPath);
+  if (relativePath.startsWith('..') || isAbsolute(relativePath)) {
+    return null;
+  }
+  return { resolvedPath, relativePath };
+}
+
 // Maximum hook data size (prevents oversized SSE broadcasts)
 const MAX_HOOK_DATA_SIZE = 8 * 1024;
 
@@ -144,6 +185,26 @@ export function sanitizeHookData(data: Record<string, unknown> | null | undefine
   return safeFields;
 }
 
+/**
+ * Toggles a service (watcher/manager) on or off based on an enabled flag.
+ * Logs start/stop to console with the given label. Runs an optional callback after starting.
+ */
+export function toggleService(
+  enabled: boolean,
+  service: { isRunning(): boolean; start(): void; stop(): void },
+  label: string,
+  onStart?: () => void
+): void {
+  if (enabled && !service.isRunning()) {
+    service.start();
+    onStart?.();
+    console.log(`${label} started via settings change`);
+  } else if (!enabled && service.isRunning()) {
+    service.stop();
+    console.log(`${label} stopped via settings change`);
+  }
+}
+
 /**
  * Auto-configure Ralph tracker for a session.
  *

src/web/routes/case-routes.ts

@@ -14,7 +14,7 @@ import { ApiErrorCode, createErrorResponse, getErrorMessage } from '../../types.
 import { CreateCaseSchema, LinkCaseSchema } from '../schemas.js';
 import { generateClaudeMd } from '../../templates/claude-md.js';
 import { writeHooksConfig } from '../../hooks-config.js';
-import { CASES_DIR, validatePathWithinBase, parseBody } from '../route-helpers.js';
+import { CASES_DIR, validatePathWithinBase, parseBody, readJsonConfig } from '../route-helpers.js';
 import { SseEvent } from '../sse-events.js';
 import type { EventPort, ConfigPort } from '../ports/index.js';
 
@@ -22,15 +22,7 @@ const LINKED_CASES_FILE = join(homedir(), '.codeman', 'linked-cases.json');
 
 /** Read and parse linked-cases.json, returning empty object on missing/invalid file. */
 async function readLinkedCases(): Promise<Record<string, string>> {
-  try {
-    return JSON.parse(await fs.readFile(LINKED_CASES_FILE, 'utf-8'));
-  } catch (err) {
-    // Only warn on real I/O errors, not ENOENT (file missing) or SyntaxError (corrupted JSON)
-    if ((err as NodeJS.ErrnoException).code && (err as NodeJS.ErrnoException).code !== 'ENOENT') {
-      console.warn('[Server] Failed to read linked cases:', err);
-    }
-    return {};
-  }
+  return readJsonConfig<Record<string, string>>(LINKED_CASES_FILE, 'linked cases', {});
 }
 
 /** Resolve a case name to its directory path, checking linked cases first, then CASES_DIR. */

src/web/routes/file-routes.ts

@@ -4,12 +4,11 @@
  */
 
 import { FastifyInstance } from 'fastify';
-import { join, resolve, relative, isAbsolute } from 'node:path';
-import { realpathSync } from 'node:fs';
+import { join } from 'node:path';
 import fs from 'node:fs/promises';
 import { ApiErrorCode, createErrorResponse, getErrorMessage } from '../../types.js';
 import { fileStreamManager } from '../../file-stream-manager.js';
-import { findSessionOrFail } from '../route-helpers.js';
+import { findSessionOrFail, validateSessionFilePath } from '../route-helpers.js';
 import type { SessionPort } from '../ports/index.js';
 
 export function registerFileRoutes(app: FastifyInstance, ctx: SessionPort): void {
@@ -148,17 +147,11 @@ export function registerFileRoutes(app: FastifyInstance, ctx: SessionPort): void
     }
 
     // Validate path is within working directory (security: resolve symlinks to prevent traversal)
-    const fullPath = resolve(session.workingDir, filePath);
-    let resolvedPath: string;
-    try {
-      resolvedPath = realpathSync(fullPath);
-    } catch {
+    const validated = validateSessionFilePath(session.workingDir, filePath);
+    if (!validated) {
       return createErrorResponse(ApiErrorCode.NOT_FOUND, 'File not found');
     }
-    const relativePath = relative(session.workingDir, resolvedPath);
-    if (relativePath.startsWith('..') || isAbsolute(relativePath)) {
-      return createErrorResponse(ApiErrorCode.INVALID_INPUT, 'Path must be within working directory');
-    }
+    const { resolvedPath } = validated;
 
     try {
       const stat = await fs.stat(resolvedPath);
@@ -255,19 +248,12 @@ export function registerFileRoutes(app: FastifyInstance, ctx: SessionPort): void
     }
 
     // Validate path is within working directory (security: resolve symlinks to prevent traversal)
-    const fullPath = resolve(session.workingDir, filePath);
-    let resolvedPath: string;
-    try {
-      resolvedPath = realpathSync(fullPath);
-    } catch {
+    const validated = validateSessionFilePath(session.workingDir, filePath);
+    if (!validated) {
       reply.code(404).send(createErrorResponse(ApiErrorCode.NOT_FOUND, 'File not found'));
       return;
     }
-    const relativePath = relative(session.workingDir, resolvedPath);
-    if (relativePath.startsWith('..') || isAbsolute(relativePath)) {
-      reply.code(400).send(createErrorResponse(ApiErrorCode.INVALID_INPUT, 'Path must be within working directory'));
-      return;
-    }
+    const { resolvedPath } = validated;
 
     try {
       // Validate file size before reading (DoS protection - prevent memory exhaustion)

src/web/routes/orchestrator-routes.ts

@@ -39,43 +39,37 @@ export function registerOrchestratorRoutes(app: FastifyInstance, ctx: Orchestrat
     return loop;
   }
 
+  const EVENT_MAP: [string, (typeof SseEvent)[keyof typeof SseEvent], string[]][] = [
+    ['stateChanged', SseEvent.OrchestratorStateChanged, ['state', 'prevState']],
+    ['planProgress', SseEvent.OrchestratorPlanProgress, ['phase', 'detail']],
+    ['planReady', SseEvent.OrchestratorPlanReady, ['plan']],
+    ['phaseStarted', SseEvent.OrchestratorPhaseStarted, ['phase']],
+    ['phaseCompleted', SseEvent.OrchestratorPhaseCompleted, ['phase']],
+    ['phaseFailed', SseEvent.OrchestratorPhaseFailed, ['phase', 'reason']],
+    ['taskAssigned', SseEvent.OrchestratorTaskAssigned, ['task', 'sessionId']],
+    ['taskCompleted', SseEvent.OrchestratorTaskCompleted, ['task']],
+    ['taskFailed', SseEvent.OrchestratorTaskFailed, ['task', 'error']],
+    ['completed', SseEvent.OrchestratorCompleted, ['stats']],
+  ];
+
   let forwardingLoop: import('../../orchestrator-loop.js').OrchestratorLoop | null = null;
   function setupEventForwarding(loop: import('../../orchestrator-loop.js').OrchestratorLoop) {
     if (forwardingLoop === loop) return; // Already attached to this loop instance
     forwardingLoop = loop;
-    loop.on('stateChanged', (state, prevState) => {
-      ctx.broadcast(SseEvent.OrchestratorStateChanged, { state, prevState });
-    });
-    loop.on('planProgress', (phase, detail) => {
-      ctx.broadcast(SseEvent.OrchestratorPlanProgress, { phase, detail });
-    });
-    loop.on('planReady', (plan) => {
-      ctx.broadcast(SseEvent.OrchestratorPlanReady, { plan });
-    });
-    loop.on('phaseStarted', (phase) => {
-      ctx.broadcast(SseEvent.OrchestratorPhaseStarted, { phase });
-    });
-    loop.on('phaseCompleted', (phase) => {
-      ctx.broadcast(SseEvent.OrchestratorPhaseCompleted, { phase });
-    });
-    loop.on('phaseFailed', (phase, reason) => {
-      ctx.broadcast(SseEvent.OrchestratorPhaseFailed, { phase, reason });
-    });
+    for (const [event, sseEvent, argNames] of EVENT_MAP) {
+      // eslint-disable-next-line @typescript-eslint/no-explicit-any
+      loop.on(event, (...args: any[]) => {
+        const payload: Record<string, unknown> = {};
+        argNames.forEach((name, i) => {
+          payload[name] = args[i];
+        });
+        ctx.broadcast(sseEvent, payload);
+      });
+    }
+    // Special cases with non-trivial payload transforms
     loop.on('verificationResult', (phase, result) => {
       ctx.broadcast(SseEvent.OrchestratorVerification, { phaseId: phase.id, result });
     });
-    loop.on('taskAssigned', (task, sessionId) => {
-      ctx.broadcast(SseEvent.OrchestratorTaskAssigned, { task, sessionId });
-    });
-    loop.on('taskCompleted', (task) => {
-      ctx.broadcast(SseEvent.OrchestratorTaskCompleted, { task });
-    });
-    loop.on('taskFailed', (task, error) => {
-      ctx.broadcast(SseEvent.OrchestratorTaskFailed, { task, error });
-    });
-    loop.on('completed', (stats) => {
-      ctx.broadcast(SseEvent.OrchestratorCompleted, { stats });
-    });
     loop.on('error', (error) => {
       ctx.broadcast(SseEvent.OrchestratorError, { error: error.message });
     });

src/web/routes/system-routes.ts

@@ -24,7 +24,14 @@ import {
 import { subagentWatcher } from '../../subagent-watcher.js';
 import { imageWatcher } from '../../image-watcher.js';
 import { getLifecycleLog } from '../../session-lifecycle-log.js';
-import { findSessionOrFail, formatUptime, parseBody, SETTINGS_PATH } from '../route-helpers.js';
+import {
+  findSessionOrFail,
+  formatUptime,
+  parseBody,
+  readJsonConfig,
+  toggleService,
+  SETTINGS_PATH,
+} from '../route-helpers.js';
 import { SseEvent } from '../sse-events.js';
 import type { SessionPort, EventPort, ConfigPort, InfraPort, AuthPort } from '../ports/index.js';
 import { AUTH_COOKIE_NAME } from '../middleware/auth.js';
@@ -281,15 +288,20 @@ export function registerSystemRoutes(
 
   // ========== Stats ==========
 
-  app.get('/api/stats', async () => {
-    const activeSessionTokens: Record<string, { inputTokens?: number; outputTokens?: number; totalCost?: number }> = {};
+  function collectActiveTokens(): Record<string, { inputTokens?: number; outputTokens?: number; totalCost?: number }> {
+    const tokens: Record<string, { inputTokens?: number; outputTokens?: number; totalCost?: number }> = {};
     for (const [sessionId, session] of ctx.sessions) {
-      activeSessionTokens[sessionId] = {
+      tokens[sessionId] = {
         inputTokens: session.inputTokens,
         outputTokens: session.outputTokens,
         totalCost: session.totalCost,
       };
     }
+    return tokens;
+  }
+
+  app.get('/api/stats', async () => {
+    const activeSessionTokens = collectActiveTokens();
     return {
       success: true,
       stats: ctx.store.getAggregateStats(activeSessionTokens),
@@ -298,14 +310,7 @@ export function registerSystemRoutes(
   });
 
   app.get('/api/token-stats', async () => {
-    const activeSessionTokens: Record<string, { inputTokens?: number; outputTokens?: number; totalCost?: number }> = {};
-    for (const [sessionId, session] of ctx.sessions) {
-      activeSessionTokens[sessionId] = {
-        inputTokens: session.inputTokens,
-        outputTokens: session.outputTokens,
-        totalCost: session.totalCost,
-      };
-    }
+    const activeSessionTokens = collectActiveTokens();
     return {
       success: true,
       daily: ctx.store.getDailyStats(30),
@@ -393,15 +398,7 @@ export function registerSystemRoutes(
   // ========== Settings ==========
 
   app.get('/api/settings', async () => {
-    try {
-      const content = await fs.readFile(SETTINGS_PATH, 'utf-8');
-      return JSON.parse(content);
-    } catch (err) {
-      if ((err as NodeJS.ErrnoException).code !== 'ENOENT') {
-        console.error('Failed to read settings:', err);
-      }
-    }
-    return {};
+    return readJsonConfig(SETTINGS_PATH, 'settings', {});
   });
 
   app.put('/api/settings', async (req) => {
@@ -422,30 +419,17 @@ export function registerSystemRoutes(
       await fs.writeFile(SETTINGS_PATH, JSON.stringify(merged, null, 2));
 
       // Handle subagent tracking toggle dynamically
-      const subagentEnabled = settings.subagentTrackingEnabled ?? true;
-      if (subagentEnabled && !subagentWatcher.isRunning()) {
-        subagentWatcher.start();
-        console.log('Subagent watcher started via settings change');
-      } else if (!subagentEnabled && subagentWatcher.isRunning()) {
-        subagentWatcher.stop();
-        console.log('Subagent watcher stopped via settings change');
-      }
+      toggleService((settings.subagentTrackingEnabled as boolean) ?? true, subagentWatcher, 'Subagent watcher');
 
       // Handle image watcher toggle dynamically
-      const imageWatcherEnabled = settings.imageWatcherEnabled ?? false;
-      if (imageWatcherEnabled && !imageWatcher.isRunning()) {
-        imageWatcher.start();
+      toggleService((settings.imageWatcherEnabled as boolean) ?? false, imageWatcher, 'Image watcher', () => {
         // Re-watch all active sessions that have image watcher enabled
         for (const session of ctx.sessions.values()) {
           if (session.imageWatcherEnabled) {
             imageWatcher.watchSession(session.id, session.workingDir);
           }
         }
-        console.log('Image watcher started via settings change');
-      } else if (!imageWatcherEnabled && imageWatcher.isRunning()) {
-        imageWatcher.stop();
-        console.log('Image watcher stopped via settings change');
-      }
+      });
 
       // Handle tunnel toggle dynamically
       if ('tunnelEnabled' in settings) {
@@ -472,16 +456,8 @@ export function registerSystemRoutes(
   // ========== Model Configuration ==========
 
   app.get('/api/execution/model-config', async () => {
-    try {
-      const content = await fs.readFile(SETTINGS_PATH, 'utf-8');
-      const settings = JSON.parse(content);
-      return { success: true, data: settings.modelConfig || {} };
-    } catch (err) {
-      if ((err as NodeJS.ErrnoException).code !== 'ENOENT') {
-        console.error('Failed to read model config:', err);
-      }
-      return { success: true, data: {} };
-    }
+    const settings = await readJsonConfig<Record<string, unknown>>(SETTINGS_PATH, 'model config', {});
+    return { success: true, data: settings.modelConfig || {} };
   });
 
   app.put('/api/execution/model-config', async (req) => {
@@ -545,15 +521,7 @@ export function registerSystemRoutes(
   // ========== Subagent Window State Persistence ==========
 
   app.get('/api/subagent-window-states', async () => {
-    try {
-      const content = await fs.readFile(windowStatesPath, 'utf-8');
-      return JSON.parse(content);
-    } catch (err) {
-      if ((err as NodeJS.ErrnoException).code !== 'ENOENT') {
-        console.error('Failed to read subagent window states:', err);
-      }
-    }
-    return { minimized: {}, open: [] };
+    return readJsonConfig(windowStatesPath, 'subagent window states', { minimized: {}, open: [] });
   });
 
   app.put('/api/subagent-window-states', async (req) => {
@@ -573,15 +541,7 @@ export function registerSystemRoutes(
   // ========== Subagent Parent Associations ==========
 
   app.get('/api/subagent-parents', async () => {
-    try {
-      const content = await fs.readFile(parentMapPath, 'utf-8');
-      return JSON.parse(content);
-    } catch (err) {
-      if ((err as NodeJS.ErrnoException).code !== 'ENOENT') {
-        console.error('Failed to read subagent parent map:', err);
-      }
-    }
-    return {};
+    return readJsonConfig(parentMapPath, 'subagent parent map', {});
   });
 
   app.put('/api/subagent-parents', async (req) => {

src/web/session-listener-wiring.ts

@@ -0,0 +1,392 @@
+/**
+ * @fileoverview Session event listener wiring — creates, attaches, and detaches session listeners.
+ *
+ * Extracted from server.ts for modularity. Provides:
+ * - `SessionListenerRefs` interface (named listener references for leak-free cleanup)
+ * - `createSessionListeners()` — builds all 25 listener handlers via dependency injection
+ * - `attachSessionListeners()` / `detachSessionListeners()` — symmetric attach/detach
+ *
+ * The detach function deduplicates a pattern that was previously copy-pasted 3 times
+ * in server.ts (_doCleanupSession, exit handler, stop()).
+ *
+ * @dependencies session.ts (Session, event types), sse-events.ts, types.ts
+ * @consumedby web/server.ts (WebServer delegates listener lifecycle here)
+ *
+ * @module web/session-listener-wiring
+ */
+
+import type {
+  Session,
+  ClaudeMessage,
+  BackgroundTask,
+  RalphTrackerState,
+  RalphTodoItem,
+  ActiveBashTool,
+} from '../session.js';
+import type { RalphStatusBlock, CircuitBreakerStatus } from '../types.js';
+import { SseEvent } from './sse-events.js';
+import { getLifecycleLog } from '../session-lifecycle-log.js';
+import { fileStreamManager } from '../file-stream-manager.js';
+
+/** Stored listener references for session cleanup (prevents memory leaks) */
+export interface SessionListenerRefs {
+  terminal: (data: string) => void;
+  clearTerminal: () => void;
+  needsRefresh: () => void;
+  message: (msg: ClaudeMessage) => void;
+  error: (error: string) => void;
+  completion: (result: string, cost: number) => void;
+  exit: (code: number | null) => void;
+  working: () => void;
+  idle: () => void;
+  taskCreated: (task: BackgroundTask) => void;
+  taskUpdated: (task: BackgroundTask) => void;
+  taskCompleted: (task: BackgroundTask) => void;
+  taskFailed: (task: BackgroundTask, error: string) => void;
+  autoClear: (data: { tokens: number; threshold: number }) => void;
+  autoCompact: (data: { tokens: number; threshold: number; prompt?: string }) => void;
+  cliInfoUpdated: (data: { version?: string; model?: string; accountType?: string; latestVersion?: string }) => void;
+  ralphLoopUpdate: (state: RalphTrackerState) => void;
+  ralphTodoUpdate: (todos: RalphTodoItem[]) => void;
+  ralphCompletionDetected: (phrase: string) => void;
+  ralphStatusBlockDetected: (block: RalphStatusBlock) => void;
+  ralphCircuitBreakerUpdate: (status: CircuitBreakerStatus) => void;
+  ralphExitGateMet: (data: { completionIndicators: number; exitSignal: boolean }) => void;
+  bashToolStart: (tool: ActiveBashTool) => void;
+  bashToolEnd: (tool: ActiveBashTool) => void;
+  bashToolsUpdate: (tools: ActiveBashTool[]) => void;
+}
+
+/** Dependencies injected by WebServer — keeps listener creation decoupled from server internals. */
+export interface SessionListenerDeps {
+  broadcast(event: string, data: unknown): void;
+  batchTerminalData(sessionId: string, data: string): void;
+  batchTaskUpdate(sessionId: string, task: BackgroundTask): void;
+  broadcastSessionStateDebounced(sessionId: string): void;
+  sendPushNotifications(event: string, data: Record<string, unknown>): void;
+  persistSessionState(session: Session): void;
+  getSessionStateWithRespawn(session: Session): unknown;
+  getRunSummaryTracker(sessionId: string): import('../run-summary.js').RunSummaryTracker | undefined;
+  stopTranscriptWatcher(sessionId: string): void;
+  cleanupSessionBatches(sessionId: string): void;
+  cancelPersistDebounce(sessionId: string): void;
+  removeRunSummaryTracker(sessionId: string): void;
+  removeSessionListenerRefs(sessionId: string): void;
+  cleanupRespawnOnExit(sessionId: string): void;
+  getStore(): import('../state-store.js').StateStore;
+}
+
+/**
+ * Creates all 25 session listener handlers, capturing dependencies via closure.
+ * Call `attachSessionListeners()` after to wire them to the session.
+ */
+export function createSessionListeners(session: Session, deps: SessionListenerDeps): SessionListenerRefs {
+  return {
+    // ─── Terminal Output ─────────────────────────────────────
+
+    /** Batches PTY output → broadcasts `session:terminal` at 16-50ms intervals */
+    terminal: (data) => {
+      deps.batchTerminalData(session.id, data);
+    },
+
+    /** Broadcasts `session:clearTerminal` — tells clients to wipe their xterm buffer (after mux attach) */
+    clearTerminal: () => {
+      deps.broadcast(SseEvent.SessionClearTerminal, { id: session.id });
+    },
+
+    /** Broadcasts `session:needsRefresh` — tells clients to reload buffer */
+    needsRefresh: () => {
+      deps.broadcast(SseEvent.SessionNeedsRefresh, { id: session.id });
+    },
+
+    // ─── Session Messages & Errors ──────────────────────────
+
+    /** Broadcasts `session:message` — structured Claude JSON messages (assistant, tool_use, etc.) */
+    message: (msg: ClaudeMessage) => {
+      deps.broadcast(SseEvent.SessionMessage, { id: session.id, message: msg });
+    },
+
+    /** Broadcasts `session:error` + sends push notification */
+    error: (error) => {
+      deps.broadcast(SseEvent.SessionError, { id: session.id, error });
+      deps.sendPushNotifications(SseEvent.SessionError, {
+        sessionId: session.id,
+        sessionName: session.name,
+        error: String(error),
+      });
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker) tracker.recordError('Session error', String(error));
+    },
+
+    /** Broadcasts `session:completion` + `session:updated` — prompt finished, persists state */
+    completion: (result, cost) => {
+      deps.broadcast(SseEvent.SessionCompletion, { id: session.id, result, cost });
+      deps.broadcast(SseEvent.SessionUpdated, deps.getSessionStateWithRespawn(session));
+      deps.persistSessionState(session);
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker) tracker.recordTokens(session.inputTokens, session.outputTokens);
+    },
+
+    // ─── Session Lifecycle ──────────────────────────────────
+
+    /** Broadcasts `session:exit` + `session:updated` — PTY process exited; cleans up respawn, timers, listeners */
+    exit: (code) => {
+      getLifecycleLog().log({
+        event: 'exit',
+        sessionId: session.id,
+        name: session.name,
+        exitCode: code,
+      });
+      // Wrap in try/catch to ensure cleanup always happens
+      try {
+        deps.broadcast(SseEvent.SessionExit, { id: session.id, code });
+        deps.broadcast(SseEvent.SessionUpdated, deps.getSessionStateWithRespawn(session));
+        deps.persistSessionState(session);
+      } catch (err) {
+        console.error(`[Server] Error broadcasting session exit for ${session.id}:`, err);
+      }
+
+      // Always clean up respawn controller, even if broadcast failed
+      try {
+        deps.cleanupRespawnOnExit(session.id);
+      } catch (err) {
+        console.error(`[Server] Error cleaning up respawn controller for ${session.id}:`, err);
+      }
+
+      // Clean up per-session resources that are stale after PTY exit.
+      try {
+        // Transcript watcher is tied to the specific PTY run
+        deps.stopTranscriptWatcher(session.id);
+
+        // Finalize run summary tracker
+        deps.removeRunSummaryTracker(session.id);
+
+        // Flush/clear terminal batching state (no more output coming)
+        deps.cleanupSessionBatches(session.id);
+
+        // Clear pending persist-debounce timer
+        deps.cancelPersistDebounce(session.id);
+
+        // Close any active file streams
+        fileStreamManager.closeSessionStreams(session.id);
+
+        // Remove stored listener refs to break closure references (prevents memory leak).
+        deps.removeSessionListenerRefs(session.id);
+      } catch (err) {
+        console.error(`[Server] Error cleaning up session resources on exit for ${session.id}:`, err);
+      }
+    },
+
+    // ─── Activity State ─────────────────────────────────────
+
+    /** Broadcasts `session:working` — Claude started processing */
+    working: () => {
+      deps.broadcast(SseEvent.SessionWorking, { id: session.id });
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker) {
+        tracker.recordWorking();
+        tracker.recordTokens(session.inputTokens, session.outputTokens);
+      }
+    },
+
+    /** Broadcasts `session:idle` — Claude finished processing, waiting for input */
+    idle: () => {
+      deps.broadcast(SseEvent.SessionIdle, { id: session.id });
+      deps.broadcastSessionStateDebounced(session.id);
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker) {
+        tracker.recordIdle();
+        tracker.recordTokens(session.inputTokens, session.outputTokens);
+      }
+    },
+
+    // ─── Background Task Events ──────────────────────────────
+
+    /** Broadcasts `task:created` — new background task discovered */
+    taskCreated: (task: BackgroundTask) => {
+      deps.broadcast(SseEvent.TaskCreated, { sessionId: session.id, task });
+      deps.broadcastSessionStateDebounced(session.id);
+    },
+
+    /** Batched broadcast of `task:updated` — high-frequency progress updates */
+    taskUpdated: (task: BackgroundTask) => {
+      deps.batchTaskUpdate(session.id, task);
+    },
+
+    /** Broadcasts `task:completed` — background task finished successfully */
+    taskCompleted: (task: BackgroundTask) => {
+      deps.broadcast(SseEvent.TaskCompleted, { sessionId: session.id, task });
+      deps.broadcastSessionStateDebounced(session.id);
+    },
+
+    /** Broadcasts `task:failed` — background task errored */
+    taskFailed: (task: BackgroundTask, error: string) => {
+      deps.broadcast(SseEvent.TaskFailed, { sessionId: session.id, task, error });
+      deps.broadcastSessionStateDebounced(session.id);
+    },
+
+    // ─── Auto-Operations ────────────────────────────────────
+
+    /** Broadcasts `session:autoClear` — context window auto-cleared at token threshold */
+    autoClear: (data: { tokens: number; threshold: number }) => {
+      deps.broadcast(SseEvent.SessionAutoClear, { sessionId: session.id, ...data });
+      deps.broadcastSessionStateDebounced(session.id);
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker) tracker.recordAutoClear(data.tokens, data.threshold);
+    },
+
+    /** Broadcasts `session:autoCompact` — context window auto-compacted at token threshold */
+    autoCompact: (data: { tokens: number; threshold: number; prompt?: string }) => {
+      deps.broadcast(SseEvent.SessionAutoCompact, { sessionId: session.id, ...data });
+      deps.broadcastSessionStateDebounced(session.id);
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker) tracker.recordAutoCompact(data.tokens, data.threshold);
+    },
+
+    // ─── CLI Info ────────────────────────────────────────────
+
+    /** Broadcasts `session:cliInfo` — Claude Code version, model, account type parsed from terminal */
+    cliInfoUpdated: (data: { version?: string; model?: string; accountType?: string; latestVersion?: string }) => {
+      deps.broadcast(SseEvent.SessionCliInfo, { sessionId: session.id, ...data });
+      deps.broadcastSessionStateDebounced(session.id);
+    },
+
+    // ─── Ralph Tracking Events ──────────────────────────────
+
+    /** Broadcasts `session:ralphLoopUpdate` — Ralph tracker loop state changed (iteration, phase) */
+    ralphLoopUpdate: (state: RalphTrackerState) => {
+      deps.broadcast(SseEvent.SessionRalphLoopUpdate, { sessionId: session.id, state });
+      deps.getStore().updateRalphState(session.id, { loop: state });
+    },
+
+    /** Broadcasts `session:ralphTodoUpdate` — todo items added, completed, or modified */
+    ralphTodoUpdate: (todos: RalphTodoItem[]) => {
+      deps.broadcast(SseEvent.SessionRalphTodoUpdate, { sessionId: session.id, todos });
+      deps.getStore().updateRalphState(session.id, { todos });
+    },
+
+    /** Broadcasts `session:ralphCompletionDetected` + push notification — completion phrase matched */
+    ralphCompletionDetected: (phrase: string) => {
+      deps.broadcast(SseEvent.SessionRalphCompletionDetected, { sessionId: session.id, phrase });
+      deps.sendPushNotifications(SseEvent.SessionRalphCompletionDetected, {
+        sessionId: session.id,
+        sessionName: session.name,
+        phrase,
+      });
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker) tracker.recordRalphCompletion(phrase);
+    },
+
+    /** Broadcasts `session:ralphStatusUpdate` — RALPH_STATUS block parsed from output */
+    ralphStatusBlockDetected: (block: RalphStatusBlock) => {
+      deps.broadcast(SseEvent.SessionRalphStatusUpdate, { sessionId: session.id, block });
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker) {
+        tracker.addEvent(
+          block.status === 'BLOCKED' ? 'warning' : 'idle_detected',
+          block.status === 'BLOCKED' ? 'warning' : 'info',
+          `Ralph Status: ${block.status}`,
+          `Tasks: ${block.tasksCompletedThisLoop}, Files: ${block.filesModified}, Tests: ${block.testsStatus}`
+        );
+      }
+    },
+
+    /** Broadcasts `session:circuitBreakerUpdate` — circuit breaker state changed (CLOSED/HALF_OPEN/OPEN) */
+    ralphCircuitBreakerUpdate: (status: CircuitBreakerStatus) => {
+      deps.broadcast(SseEvent.SessionCircuitBreakerUpdate, { sessionId: session.id, status });
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker && status.state === 'OPEN') {
+        tracker.addEvent('warning', 'warning', 'Circuit Breaker Opened', status.reason);
+      }
+    },
+
+    /** Broadcasts `session:exitGateMet` — all completion indicators met, ready to exit */
+    ralphExitGateMet: (data: { completionIndicators: number; exitSignal: boolean }) => {
+      deps.broadcast(SseEvent.SessionExitGateMet, { sessionId: session.id, ...data });
+      const tracker = deps.getRunSummaryTracker(session.id);
+      if (tracker) {
+        tracker.addEvent(
+          'ralph_completion',
+          'success',
+          'Exit Gate Met',
+          `Indicators: ${data.completionIndicators}, EXIT_SIGNAL: ${data.exitSignal}`
+        );
+      }
+    },
+
+    // ─── Bash Tool Tracking ────────────────────────────────
+
+    /** Broadcasts `session:bashToolStart` — bash tool invocation started */
+    bashToolStart: (tool: ActiveBashTool) => {
+      deps.broadcast(SseEvent.SessionBashToolStart, { sessionId: session.id, tool });
+    },
+
+    /** Broadcasts `session:bashToolEnd` — bash tool invocation completed */
+    bashToolEnd: (tool: ActiveBashTool) => {
+      deps.broadcast(SseEvent.SessionBashToolEnd, { sessionId: session.id, tool });
+    },
+
+    /** Broadcasts `session:bashToolsUpdate` — full active bash tools list refreshed */
+    bashToolsUpdate: (tools: ActiveBashTool[]) => {
+      deps.broadcast(SseEvent.SessionBashToolsUpdate, { sessionId: session.id, tools });
+    },
+  };
+}
+
+/** Attach all listeners to a session. */
+export function attachSessionListeners(session: Session, refs: SessionListenerRefs): void {
+  session.on('terminal', refs.terminal);
+  session.on('clearTerminal', refs.clearTerminal);
+  session.on('needsRefresh', refs.needsRefresh);
+  session.on('message', refs.message);
+  session.on('error', refs.error);
+  session.on('completion', refs.completion);
+  session.on('exit', refs.exit);
+  session.on('working', refs.working);
+  session.on('idle', refs.idle);
+  session.on('taskCreated', refs.taskCreated);
+  session.on('taskUpdated', refs.taskUpdated);
+  session.on('taskCompleted', refs.taskCompleted);
+  session.on('taskFailed', refs.taskFailed);
+  session.on('autoClear', refs.autoClear);
+  session.on('autoCompact', refs.autoCompact);
+  session.on('cliInfoUpdated', refs.cliInfoUpdated);
+  session.on('ralphLoopUpdate', refs.ralphLoopUpdate);
+  session.on('ralphTodoUpdate', refs.ralphTodoUpdate);
+  session.on('ralphCompletionDetected', refs.ralphCompletionDetected);
+  session.on('ralphStatusBlockDetected', refs.ralphStatusBlockDetected);
+  session.on('ralphCircuitBreakerUpdate', refs.ralphCircuitBreakerUpdate);
+  session.on('ralphExitGateMet', refs.ralphExitGateMet);
+  session.on('bashToolStart', refs.bashToolStart);
+  session.on('bashToolEnd', refs.bashToolEnd);
+  session.on('bashToolsUpdate', refs.bashToolsUpdate);
+}
+
+/** Detach all listeners from a session (prevents memory leaks from closure references). */
+export function detachSessionListeners(session: Session, refs: SessionListenerRefs): void {
+  session.off('terminal', refs.terminal);
+  session.off('clearTerminal', refs.clearTerminal);
+  session.off('needsRefresh', refs.needsRefresh);
+  session.off('message', refs.message);
+  session.off('error', refs.error);
+  session.off('completion', refs.completion);
+  session.off('exit', refs.exit);
+  session.off('working', refs.working);
+  session.off('idle', refs.idle);
+  session.off('taskCreated', refs.taskCreated);
+  session.off('taskUpdated', refs.taskUpdated);
+  session.off('taskCompleted', refs.taskCompleted);
+  session.off('taskFailed', refs.taskFailed);
+  session.off('autoClear', refs.autoClear);
+  session.off('autoCompact', refs.autoCompact);
+  session.off('cliInfoUpdated', refs.cliInfoUpdated);
+  session.off('ralphLoopUpdate', refs.ralphLoopUpdate);
+  session.off('ralphTodoUpdate', refs.ralphTodoUpdate);
+  session.off('ralphCompletionDetected', refs.ralphCompletionDetected);
+  session.off('ralphStatusBlockDetected', refs.ralphStatusBlockDetected);
+  session.off('ralphCircuitBreakerUpdate', refs.ralphCircuitBreakerUpdate);
+  session.off('ralphExitGateMet', refs.ralphExitGateMet);
+  session.off('bashToolStart', refs.bashToolStart);
+  session.off('bashToolEnd', refs.bashToolEnd);
+  session.off('bashToolsUpdate', refs.bashToolsUpdate);
+}

src/web/sse-stream-manager.ts

@@ -0,0 +1,488 @@
+/**
+ * @fileoverview SSE stream manager — owns all SSE client state, broadcasting, and event batching.
+ *
+ * Extracted from server.ts for modularity. Handles:
+ * - SSE client connection tracking with subscription filtering
+ * - Backpressure-aware message delivery
+ * - Terminal data batching with adaptive intervals (16-50ms for 60fps)
+ * - Task update and session state batching
+ * - Dead client cleanup and keepalive
+ * - Cloudflare tunnel padding for proxy buffer flushing
+ *
+ * @dependencies CleanupManager (managed timers), config/server-timing (constants)
+ * @consumedby web/server.ts (WebServer delegates all SSE operations here)
+ *
+ * @module web/sse-stream-manager
+ */
+
+import type { FastifyReply } from 'fastify';
+import type { BackgroundTask } from '../session.js';
+import { CleanupManager, StaleExpirationMap } from '../utils/index.js';
+import { SseEvent } from './sse-events.js';
+import {
+  TERMINAL_BATCH_INTERVAL,
+  TASK_UPDATE_BATCH_INTERVAL,
+  STATE_UPDATE_DEBOUNCE_INTERVAL,
+  BATCH_FLUSH_THRESHOLD,
+  SSE_PADDING_SIZE,
+  INACTIVITY_TIMEOUT_MS,
+} from '../config/server-timing.js';
+
+// SSE padding for Cloudflare tunnel buffer flushing.
+// Cloudflare quick tunnels buffer small SSE responses, causing lag for real-time events.
+// Appending SSE comment padding (ignored by EventSource) forces the proxy to flush.
+// Pre-computed once at startup to avoid repeated string allocation.
+const SSE_PADDING = ':' + 'p'.repeat(SSE_PADDING_SIZE) + '\n';
+
+/** Dependencies injected by WebServer — keeps SseStreamManager decoupled from session/respawn state. */
+export interface SseStreamManagerDeps {
+  /** Get session state with respawn info for session:updated broadcasts */
+  getSessionStateWithRespawn(sessionId: string): unknown;
+}
+
+export class SseStreamManager {
+  // ─── SSE Client Tracking ────────────────────────────────
+  /**
+   * SSE clients mapped to their session subscription filter.
+   * Value is a Set of session IDs the client wants events for,
+   * or `null` meaning "receive all events" (backwards-compatible default).
+   */
+  private sseClients: Map<FastifyReply, Set<string> | null> = new Map();
+  /** SSE clients connecting from non-localhost (i.e. through tunnel) */
+  private remoteSseClients: Set<FastifyReply> = new Set();
+  /** Clients with backpressure — skip writes until 'drain' fires */
+  private backpressuredClients: Set<FastifyReply> = new Set();
+
+  // ─── Tunnel State ───────────────────────────────────────
+  /** Cached tunnel active state — updated on TunnelStarted/TunnelStopped to avoid getUrl() on every broadcast */
+  private _isTunnelActive: boolean = false;
+
+  // ─── Terminal Batching ──────────────────────────────────
+  private terminalBatches: Map<string, string[]> = new Map();
+  private terminalBatchSizes: Map<string, number> = new Map(); // Running total avoids O(n) reduce per push
+  private terminalBatchTimers: Map<string, NodeJS.Timeout> = new Map(); // Per-session timers (staggered flushes)
+  // Adaptive batching: track rapid events to extend batch window (per-session)
+  // StaleExpirationMap auto-cleans entries for sessions that stop generating output
+  private lastTerminalEventTime: StaleExpirationMap<string, number>;
+
+  // ─── Event Batching ─────────────────────────────────────
+  private taskUpdateBatches: Map<string, { sessionId: string; task: BackgroundTask }> = new Map();
+  private taskUpdateBatchTimerId: string | null = null;
+  // State update batching (reduce expensive toDetailedState() serialization)
+  private stateUpdatePending: Set<string> = new Set();
+  private stateUpdateTimerId: string | null = null;
+
+  // ─── Lifecycle ──────────────────────────────────────────
+  private _isStopping: boolean = false;
+
+  constructor(
+    private deps: SseStreamManagerDeps,
+    private cleanup: CleanupManager
+  ) {
+    this.lastTerminalEventTime = new StaleExpirationMap({
+      ttlMs: INACTIVITY_TIMEOUT_MS, // 5 minutes - auto-expire stale session timing data
+      refreshOnGet: false, // Don't refresh on reads, only on explicit sets
+    });
+  }
+
+  // ========== SSE Connection Management ==========
+
+  get clientCount(): number {
+    return this.sseClients.size;
+  }
+
+  get remoteClientCount(): number {
+    return this.remoteSseClients.size;
+  }
+
+  get isTunnelActive(): boolean {
+    return this._isTunnelActive;
+  }
+
+  setTunnelActive(active: boolean): void {
+    this._isTunnelActive = active;
+  }
+
+  addClient(reply: FastifyReply, sessionFilter: Set<string> | null, isRemote: boolean): void {
+    this.sseClients.set(reply, sessionFilter);
+    if (isRemote) {
+      this.remoteSseClients.add(reply);
+    }
+  }
+
+  removeClient(reply: FastifyReply): void {
+    this.sseClients.delete(reply);
+    this.remoteSseClients.delete(reply);
+    this.backpressuredClients.delete(reply);
+  }
+
+  /** Send a single SSE event to a specific client. */
+  sendSSE(reply: FastifyReply, event: string, data: unknown): void {
+    try {
+      reply.raw.write(`event: ${event}\ndata: ${JSON.stringify(data)}\n\n`);
+    } catch {
+      this.sseClients.delete(reply);
+      this.remoteSseClients.delete(reply);
+    }
+  }
+
+  /** Send pre-formatted tunnel padding to a specific client. */
+  sendPadding(reply: FastifyReply): void {
+    if (!this._isTunnelActive) return;
+    try {
+      reply.raw.write(SSE_PADDING);
+    } catch {
+      /* client gone */
+    }
+  }
+
+  // Optimized: send pre-formatted SSE message to a client
+  // Returns false if client is backpressured or dead
+  private sendSSEPreformatted(reply: FastifyReply, message: string): void {
+    // Skip backpressured clients to prevent unbounded memory growth.
+    // Terminal data dropped here is recovered via session:needsRefresh on drain.
+    if (this.backpressuredClients.has(reply)) return;
+
+    try {
+      const ok = reply.raw.write(message);
+      if (!ok) {
+        // Buffer is full — mark as backpressured, resume on drain
+        this.backpressuredClients.add(reply);
+        reply.raw.once('drain', () => {
+          this.backpressuredClients.delete(reply);
+          // Client may have missed terminal data during backpressure.
+          // Tell it to reload the active session's buffer to recover.
+          try {
+            const drainPadding = this._isTunnelActive ? SSE_PADDING : '';
+            reply.raw.write(`event: ${SseEvent.SessionNeedsRefresh}\ndata: {}\n\n${drainPadding}`);
+          } catch {
+            /* client gone */
+          }
+        });
+      }
+    } catch {
+      this.sseClients.delete(reply);
+      this.remoteSseClients.delete(reply);
+      this.backpressuredClients.delete(reply);
+    }
+  }
+
+  // ========== Broadcasting ==========
+
+  broadcast(event: string, data: unknown): void {
+    // Skip serialization entirely when no clients are listening
+    if (this.sseClients.size === 0) return;
+
+    // Performance optimization: serialize JSON once for all clients.
+    // Only append Cloudflare tunnel padding for latency-sensitive events —
+    // Recovery events need immediate proxy flush; low-frequency metadata events
+    // (session:created, ralph:*, respawn:*, etc.) don't need padding.
+    // Note: session:terminal has its own padding in flushSessionTerminalBatch().
+    const needsPadding = this._isTunnelActive && event === SseEvent.SessionNeedsRefresh;
+    const padding = needsPadding ? SSE_PADDING : '';
+    let message: string;
+    try {
+      message = `event: ${event}\ndata: ${JSON.stringify(data)}\n\n` + padding;
+    } catch (err) {
+      // Handle circular references or non-serializable values
+      console.error(`[Server] Failed to serialize SSE event "${event}":`, err);
+      return;
+    }
+    // Extract sessionId from event data for subscription filtering.
+    const eventSessionId = this.extractSessionId(event, data);
+
+    for (const [client, filter] of this.sseClients) {
+      // No filter (null) = receive everything. Otherwise, skip if event is
+      // session-scoped and the session isn't in the client's subscription set.
+      if (filter && eventSessionId && !filter.has(eventSessionId)) continue;
+      this.sendSSEPreformatted(client, message);
+    }
+  }
+
+  /**
+   * Extract the session ID from an event's data payload for subscription filtering.
+   * Returns the sessionId string if the event is session-scoped, or null for global events.
+   */
+  private extractSessionId(event: string, data: unknown): string | null {
+    if (data == null || typeof data !== 'object') return null;
+    const record = data as Record<string, unknown>;
+
+    // Most session-scoped events use `sessionId`
+    if (typeof record.sessionId === 'string') return record.sessionId;
+
+    // Session lifecycle events (session:*) use `id` from the session state object
+    if (typeof record.id === 'string' && event.startsWith('session:')) return record.id;
+
+    // No session ID found — treat as global event (sent to all clients)
+    return null;
+  }
+
+  // ========== Terminal Data Batching ==========
+
+  // Batch terminal data for better performance (60fps)
+  // Uses per-session timers with adaptive intervals to prevent thundering herd:
+  // each session flushes independently rather than all sessions flushing in one burst.
+  batchTerminalData(sessionId: string, data: string): void {
+    // Skip if server is stopping
+    if (this._isStopping) return;
+
+    let chunks = this.terminalBatches.get(sessionId);
+    if (!chunks) {
+      chunks = [];
+      this.terminalBatches.set(sessionId, chunks);
+    }
+    chunks.push(data);
+    const prevSize = this.terminalBatchSizes.get(sessionId) ?? 0;
+    const totalLength = prevSize + data.length;
+    this.terminalBatchSizes.set(sessionId, totalLength);
+
+    // Adaptive batching: detect rapid events and extend batch window (per-session)
+    const now = Date.now();
+    const lastEvent = this.lastTerminalEventTime.get(sessionId) ?? 0;
+    const eventGap = now - lastEvent;
+    this.lastTerminalEventTime.set(sessionId, now);
+
+    // Adjust batch interval based on event frequency (per-session)
+    // Rapid events (<10ms gap) = 50ms batch, moderate (<20ms) = 32ms, else 16ms
+    let sessionInterval: number;
+    if (eventGap > 0 && eventGap < 10) {
+      sessionInterval = 50;
+    } else if (eventGap > 0 && eventGap < 20) {
+      sessionInterval = 32;
+    } else {
+      sessionInterval = TERMINAL_BATCH_INTERVAL;
+    }
+
+    // Flush immediately if batch is large for responsiveness
+    if (totalLength > BATCH_FLUSH_THRESHOLD) {
+      const existingTimer = this.terminalBatchTimers.get(sessionId);
+      if (existingTimer) {
+        clearTimeout(existingTimer);
+        this.terminalBatchTimers.delete(sessionId);
+      }
+      this.flushSessionTerminalBatch(sessionId);
+      return;
+    }
+
+    // Start per-session batch timer if not already running
+    // Each session flushes independently — prevents one busy session from
+    // forcing all sessions to flush at its rate (thundering herd)
+    if (!this.terminalBatchTimers.has(sessionId)) {
+      this.terminalBatchTimers.set(
+        sessionId,
+        setTimeout(() => {
+          this.terminalBatchTimers.delete(sessionId);
+          this.flushSessionTerminalBatch(sessionId);
+        }, sessionInterval)
+      );
+    }
+  }
+
+  /** Flush a single session's batched terminal data */
+  private flushSessionTerminalBatch(sessionId: string): void {
+    if (this._isStopping) {
+      this.terminalBatches.delete(sessionId);
+      this.terminalBatchSizes.delete(sessionId);
+      return;
+    }
+    const chunks = this.terminalBatches.get(sessionId);
+    if (chunks && chunks.length > 0) {
+      // Join chunks only at flush time (avoids O(n^2) string concatenation in batchTerminalData)
+      const data = chunks.join('');
+      // Wrap batched output in DEC 2026 synchronized output markers so xterm.js
+      // renders the entire batch atomically. Ink spinner frames (cursor-up + redraw)
+      // do NOT emit their own 2026 markers, so without this wrapper each partial
+      // cursor update renders individually, causing visible flicker.
+      // xterm.js 6.0+ handles DEC 2026 natively: it buffers everything between
+      // 2026h/2026l and renders in one pass.
+      const syncData = '\x1b[?2026h' + data + '\x1b[?2026l';
+      // Fast path: build SSE message directly without JSON.stringify on wrapper object.
+      // Only the terminal data string needs escaping; sessionId is a UUID (safe to template).
+      const escapedData = JSON.stringify(syncData);
+      // Append tunnel padding for immediate Cloudflare proxy flush —
+      // terminal data is high-frequency and latency-sensitive.
+      const padding = this._isTunnelActive ? SSE_PADDING : '';
+      const message = `event: session:terminal\ndata: {"id":"${sessionId}","data":${escapedData}}\n\n` + padding;
+      for (const [client, filter] of this.sseClients) {
+        // Skip clients that have a session filter and aren't subscribed to this session
+        if (filter && !filter.has(sessionId)) continue;
+        this.sendSSEPreformatted(client, message);
+      }
+    }
+    this.terminalBatches.delete(sessionId);
+    this.terminalBatchSizes.delete(sessionId);
+  }
+
+  // ========== Task Update Batching ==========
+
+  // Batch task:updated events at 100ms - only send latest update per task
+  // Key is sessionId:taskId to avoid collisions when multiple tasks update concurrently
+  batchTaskUpdate(sessionId: string, task: BackgroundTask): void {
+    // Skip if server is stopping
+    if (this._isStopping) return;
+
+    // Use composite key to avoid losing updates when multiple tasks update in same batch window
+    const key = `${sessionId}:${task.id}`;
+    this.taskUpdateBatches.set(key, { sessionId, task });
+
+    if (!this.taskUpdateBatchTimerId) {
+      this.taskUpdateBatchTimerId = this.cleanup.setTimeout(
+        () => {
+          this.taskUpdateBatchTimerId = null;
+          this.flushTaskUpdateBatches();
+        },
+        TASK_UPDATE_BATCH_INTERVAL,
+        { description: 'task update batch flush' }
+      );
+    }
+  }
+
+  private flushTaskUpdateBatches(): void {
+    // Skip if server is stopping (timer may have been queued before stop() was called)
+    if (this._isStopping) {
+      this.taskUpdateBatches.clear();
+      return;
+    }
+    for (const [, { sessionId, task }] of this.taskUpdateBatches) {
+      this.broadcast(SseEvent.TaskUpdated, { sessionId, task });
+    }
+    this.taskUpdateBatches.clear();
+  }
+
+  // ========== Session State Batching ==========
+
+  /**
+   * Debounce expensive session:updated broadcasts.
+   * Instead of calling toDetailedState() on every event, batch requests
+   * and only serialize once per STATE_UPDATE_DEBOUNCE_INTERVAL.
+   */
+  broadcastSessionStateDebounced(sessionId: string): void {
+    // Skip if server is stopping
+    if (this._isStopping) return;
+
+    this.stateUpdatePending.add(sessionId);
+
+    if (!this.stateUpdateTimerId) {
+      this.stateUpdateTimerId = this.cleanup.setTimeout(
+        () => {
+          this.stateUpdateTimerId = null;
+          this.flushStateUpdates();
+        },
+        STATE_UPDATE_DEBOUNCE_INTERVAL,
+        { description: 'state update debounce flush' }
+      );
+    }
+  }
+
+  private flushStateUpdates(): void {
+    // Skip if server is stopping (timer may have been queued before stop() was called)
+    if (this._isStopping) {
+      this.stateUpdatePending.clear();
+      return;
+    }
+    for (const sessionId of this.stateUpdatePending) {
+      // Single expensive serialization per batch interval
+      const state = this.deps.getSessionStateWithRespawn(sessionId);
+      if (state) {
+        this.broadcast(SseEvent.SessionUpdated, state);
+      }
+    }
+    this.stateUpdatePending.clear();
+  }
+
+  // ========== Client Health ==========
+
+  /**
+   * Clean up dead SSE clients and send keep-alive comments.
+   * Keep-alive prevents proxy/load-balancer timeouts on idle connections.
+   * Dead client cleanup prevents memory leaks from abruptly terminated connections.
+   */
+  cleanupDeadClients(): void {
+    const deadClients: FastifyReply[] = [];
+
+    for (const [client] of this.sseClients) {
+      try {
+        // Check if the underlying socket is still writable
+        const socket = client.raw.socket;
+        if (!socket || socket.destroyed || !socket.writable) {
+          deadClients.push(client);
+        } else {
+          // Send SSE comment as keep-alive. Only add padding when tunnel is
+          // active — it flushes Cloudflare proxy buffers but wastes bandwidth
+          // for direct/Tailscale connections.
+          const ka = this._isTunnelActive ? ':keepalive\n' + SSE_PADDING : ':keepalive\n\n';
+          client.raw.write(ka);
+        }
+      } catch {
+        // Error accessing socket means client is dead
+        deadClients.push(client);
+      }
+    }
+
+    // Remove dead clients
+    for (const client of deadClients) {
+      this.sseClients.delete(client);
+      this.remoteSseClients.delete(client);
+      this.backpressuredClients.delete(client);
+    }
+
+    if (deadClients.length > 0) {
+      console.log(`[Server] Cleaned up ${deadClients.length} dead SSE client(s)`);
+    }
+  }
+
+  // ========== Session Cleanup ==========
+
+  /** Clean up all batching state for a session (call on session exit or deletion). */
+  cleanupSessionBatches(sessionId: string): void {
+    this.terminalBatches.delete(sessionId);
+    this.terminalBatchSizes.delete(sessionId);
+    const batchTimer = this.terminalBatchTimers.get(sessionId);
+    if (batchTimer) {
+      clearTimeout(batchTimer);
+      this.terminalBatchTimers.delete(sessionId);
+    }
+    this.taskUpdateBatches.delete(sessionId);
+    this.stateUpdatePending.delete(sessionId);
+    this.lastTerminalEventTime.delete(sessionId);
+  }
+
+  // ========== Lifecycle ==========
+
+  setStopping(): void {
+    this._isStopping = true;
+  }
+
+  /** Graceful shutdown: notify clients, close connections, clear all state. */
+  stop(): void {
+    this._isStopping = true;
+
+    // Gracefully close all SSE connections before clearing
+    for (const [client] of this.sseClients) {
+      try {
+        // Send a final event to notify clients of shutdown
+        this.sendSSE(client, 'server:shutdown', { reason: 'Server stopping' });
+        client.raw.end();
+      } catch {
+        // Client may already be disconnected
+      }
+    }
+    this.sseClients.clear();
+    this.remoteSseClients.clear();
+    this.backpressuredClients.clear();
+
+    // Clear per-session batch timers
+    for (const timer of this.terminalBatchTimers.values()) {
+      clearTimeout(timer);
+    }
+    this.terminalBatchTimers.clear();
+    this.terminalBatches.clear();
+    this.terminalBatchSizes.clear();
+
+    this.taskUpdateBatches.clear();
+    this.stateUpdatePending.clear();
+
+    // Dispose StaleExpirationMap (stops internal cleanup timer)
+    this.lastTerminalEventTime.dispose();
+  }
+}

test/routes/system-routes.test.ts

@@ -366,6 +366,36 @@ describe('system-routes', () => {
       expect(body.success).toBe(false);
     });
 
+    it('saves lastUsedCase as partial update without overwriting other settings', async () => {
+      mockedReadFile.mockResolvedValue(
+        JSON.stringify({ showCost: true, showTokenCount: false, subagentTrackingEnabled: true }) as never
+      );
+
+      const res = await harness.app.inject({
+        method: 'PUT',
+        url: '/api/settings',
+        payload: { lastUsedCase: 'my-test-case' },
+      });
+      expect(res.statusCode).toBe(200);
+      expect(JSON.parse(res.body).success).toBe(true);
+
+      const writtenContent = JSON.parse(mockedWriteFile.mock.calls[0][1] as string);
+      expect(writtenContent.lastUsedCase).toBe('my-test-case');
+      expect(writtenContent.showCost).toBe(true);
+      expect(writtenContent.showTokenCount).toBe(false);
+      expect(writtenContent.subagentTrackingEnabled).toBe(true);
+    });
+
+    it('rejects settings with modelConfig (strict schema prevents full-object PUT)', async () => {
+      const res = await harness.app.inject({
+        method: 'PUT',
+        url: '/api/settings',
+        payload: { lastUsedCase: 'test', modelConfig: { model: 'something' } },
+      });
+      // Fastify rejects unknown fields at schema validation level (400) before handler runs
+      expect(res.statusCode).toBe(400);
+    });
+
     it('rejects non-object body', async () => {
       const res = await harness.app.inject({
         method: 'PUT',