fix(gsd): address 3 silent-crash secondary issues from #3348 post-#3696 (#4133)

* fix(ci): address 5 pipeline integrity issues from release audit

- version-stamp.mjs: regenerate package-lock.json after dev version stamp
  (mirrors the same fix applied to bump-version.mjs in #4116)

- bump-version.mjs: regenerate root and web/package-lock.json after version
  bump so both lockfiles are always in sync at release time

- pipeline.yml: add post-bump validation step that verifies all package.json
  files parse as valid JSON before the release commit is made

- pipeline.yml: split "Commit, tag, and push" — commit+tag+rebase happen
  before build, but git push is deferred until after build and npm publish
  both succeed, preventing a broken tag from landing on main

- pipeline.yml: emit a :⚠️: annotation when live LLM tests fail so
  failures are visible in the Actions UI instead of silently swallowed

Closes #4118

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

* fix(gsd): address 3 silent-crash secondary issues from #3348 post-#3696

Three gaps that remained after the double-fault fix in #3696:

1. unhandledRejection not wired — installEpipeGuard only registered
   uncaughtException; promise rejections that escaped without a catch
   were not handled by the GSD error path. Added _gsdRejectionGuard
   alongside _gsdEpipeGuard.

2. Non-fatal overcorrection — the #3696 fix replaced re-throwing with
   log-and-continue, leaving the process running in an indeterminate
   state after any non-EPIPE/non-ENOENT exception. Replaced with
   writeCrashLog + process.exit(1). writeCrashLog is extracted into
   bootstrap/crash-log.ts (zero deps) so tests can import it without
   pulling in the full extension graph.

3. unit-end not emitted after crash-with-side-effects — hameltomor
   observed that complete-milestone M001 wrote SUMMARY.md and updated
   the DB but never emitted unit-end (#3348 comment-4237533440). Added
   emitCrashRecoveredUnitEnd() in crash-recovery.ts: on the next
   auto-mode startup, if a stale lock references a unit whose
   unit-start has no matching unit-end in the journal, a synthetic
   unit-end with status "crash-recovered" is emitted before the lock
   is cleared. This closes the causal chain for downstream tooling
   and forensics without requiring changes to the lock file schema.

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

---------

Co-authored-by: Claude Sonnet 4.6 <noreply@anthropic.com>

src/resources/extensions/gsd/auto.ts

@@ -52,6 +52,7 @@ import {
   readCrashLock,
   isLockProcessAlive,
   formatCrashInfo,
+  emitCrashRecoveredUnitEnd,
 } from "./crash-recovery.js";
 import {
   acquireSessionLock,
@@ -1332,6 +1333,10 @@ export async function startAuto(
   }
 
   if (freshStartAssessment.lock) {
+    // Emit a synthetic unit-end for any unit-start that has no closing event.
+    // This closes the journal gap reported in #3348 where the worker wrote side
+    // effects (SUMMARY.md, DB updates) but died before emitting unit-end.
+    emitCrashRecoveredUnitEnd(base, freshStartAssessment.lock);
     clearLock(base);
   }
 

src/resources/extensions/gsd/bootstrap/crash-log.ts

@@ -0,0 +1,32 @@
+/**
+ * crash-log.ts — Write crash diagnostics to ~/.gsd/crash/<timestamp>.log
+ *
+ * Zero cross-dependencies: only uses Node.js built-ins so it can be imported
+ * safely from uncaughtException / unhandledRejection handlers and from tests
+ * without pulling in the full extension dependency tree.
+ */
+
+import { appendFileSync, mkdirSync } from "node:fs";
+import { homedir } from "node:os";
+import { join } from "node:path";
+
+/**
+ * Write a crash log to ~/.gsd/crash/<timestamp>.log (or $GSD_HOME/crash/).
+ * Never throws — must be safe to call from any error handler.
+ */
+export function writeCrashLog(err: Error, source: string): void {
+  try {
+    const crashDir = join(process.env.GSD_HOME ?? join(homedir(), ".gsd"), "crash");
+    mkdirSync(crashDir, { recursive: true });
+    const ts = new Date().toISOString().replace(/[:.]/g, "-");
+    const logPath = join(crashDir, `${ts}.log`);
+    const lines = [
+      `[gsd] ${source}: ${err.message}`,
+      `timestamp: ${new Date().toISOString()}`,
+      `pid: ${process.pid}`,
+      err.stack ?? "(no stack trace available)",
+      "",
+    ];
+    appendFileSync(logPath, lines.join("\n"));
+  } catch { /* never throw from crash handler */ }
+}

src/resources/extensions/gsd/bootstrap/register-extension.ts

@@ -11,6 +11,9 @@ import { registerJournalTools } from "./journal-tools.js";
 import { registerQueryTools } from "./query-tools.js";
 import { registerHooks } from "./register-hooks.js";
 import { registerShortcuts } from "./register-shortcuts.js";
+import { writeCrashLog } from "./crash-log.js";
+
+export { writeCrashLog } from "./crash-log.js";
 
 export function handleRecoverableExtensionProcessError(err: Error): boolean {
   if ((err as NodeJS.ErrnoException).code === "EPIPE") {
@@ -33,16 +36,25 @@ export function handleRecoverableExtensionProcessError(err: Error): boolean {
 function installEpipeGuard(): void {
   if (!process.listeners("uncaughtException").some((listener) => listener.name === "_gsdEpipeGuard")) {
     const _gsdEpipeGuard = (err: Error): void => {
-      if (handleRecoverableExtensionProcessError(err)) {
-        return;
-      }
-      // Log unhandled errors instead of re-throwing — throwing inside an
-      // uncaughtException handler is a fatal double-fault in Node.js (#3163).
-      process.stderr.write(`[gsd] uncaught extension error (non-fatal): ${err.message}\n`);
-      if (err.stack) process.stderr.write(`${err.stack}\n`);
+      if (handleRecoverableExtensionProcessError(err)) return;
+      // Write crash log and exit cleanly for unrecoverable errors.
+      // Logging and continuing was the original double-fault fix (#3163), but
+      // continuing in an indeterminate state is worse than a clean exit (#3348).
+      writeCrashLog(err, "uncaughtException");
+      process.exit(1);
     };
     process.on("uncaughtException", _gsdEpipeGuard);
   }
+
+  if (!process.listeners("unhandledRejection").some((listener) => listener.name === "_gsdRejectionGuard")) {
+    const _gsdRejectionGuard = (reason: unknown, _promise: Promise<unknown>): void => {
+      const err = reason instanceof Error ? reason : new Error(String(reason));
+      if (handleRecoverableExtensionProcessError(err)) return;
+      writeCrashLog(err, "unhandledRejection");
+      process.exit(1);
+    };
+    process.on("unhandledRejection", _gsdRejectionGuard);
+  }
 }
 
 export function registerGsdExtension(pi: ExtensionAPI): void {

src/resources/extensions/gsd/crash-recovery.ts

@@ -15,6 +15,7 @@ import { join } from "node:path";
 import { gsdRoot } from "./paths.js";
 import { atomicWriteSync } from "./atomic-write.js";
 import { effectiveLockFile } from "./session-lock.js";
+import { emitJournalEvent, queryJournal } from "./journal.js";
 
 export interface LockData {
   pid: number;
@@ -118,3 +119,61 @@ export function formatCrashInfo(lock: LockData): string {
 
   return lines.join("\n");
 }
+
+/**
+ * Emit a synthetic unit-end event for a unit that crashed without emitting its own.
+ *
+ * Queries the journal to find the most recent unit-start for the crashed unit.
+ * If a matching unit-end already exists (e.g. the hard timeout fired), this is a
+ * no-op. Called during crash recovery, before clearing the stale lock.
+ *
+ * Addresses the gap reported in #3348 where `unit-start` was emitted but no
+ * `unit-end` followed — side effects landed but the worker died before closeout.
+ */
+export function emitCrashRecoveredUnitEnd(basePath: string, lock: LockData): void {
+  // Skip bootstrap / starting pseudo-units — they have no meaningful unit-start event.
+  if (!lock.unitType || !lock.unitId || lock.unitType === "starting") return;
+
+  try {
+    const all = queryJournal(basePath);
+
+    // Find the most recent unit-start for this unitId
+    const starts = all.filter(
+      (e) => e.eventType === "unit-start" && e.data?.unitId === lock.unitId,
+    );
+    if (starts.length === 0) return;
+
+    const lastStart = starts[starts.length - 1];
+
+    // Check if a unit-end was already emitted (e.g. hard timeout fired after the crash)
+    const alreadyClosed = all.some(
+      (e) =>
+        e.eventType === "unit-end" &&
+        e.data?.unitId === lock.unitId &&
+        e.causedBy?.flowId === lastStart.flowId &&
+        e.causedBy?.seq === lastStart.seq,
+    );
+    if (alreadyClosed) return;
+
+    // Find the highest seq in this flow for monotonic ordering
+    const maxSeq = all
+      .filter((e) => e.flowId === lastStart.flowId)
+      .reduce((max, e) => Math.max(max, e.seq), lastStart.seq);
+
+    emitJournalEvent(basePath, {
+      ts: new Date().toISOString(),
+      flowId: lastStart.flowId,
+      seq: maxSeq + 1,
+      eventType: "unit-end",
+      data: {
+        unitType: lock.unitType,
+        unitId: lock.unitId,
+        status: "crash-recovered",
+        artifactVerified: false,
+      },
+      causedBy: { flowId: lastStart.flowId, seq: lastStart.seq },
+    });
+  } catch {
+    // Never throw from crash recovery path — journal failure must not block recovery
+  }
+}

src/resources/extensions/gsd/tests/crash-handler-secondary.test.ts

@@ -0,0 +1,235 @@
+/**
+ * Regression tests for #3348 secondary issues — crash handler gaps surfaced after #3696
+ *
+ * 1. register-extension.ts: writeCrashLog writes to ~/.gsd/crash/ directory
+ * 2. register-extension.ts: _gsdRejectionGuard registered for unhandledRejection
+ * 3. register-extension.ts: _gsdEpipeGuard exits with code 1 for unrecoverable errors (no log-and-continue)
+ * 4. crash-recovery.ts: emitCrashRecoveredUnitEnd closes open unit-start journal entries
+ */
+
+import { describe, test } from 'node:test';
+import assert from 'node:assert/strict';
+import { existsSync, mkdirSync, readFileSync, readdirSync, rmSync } from 'node:fs';
+import { join } from 'node:path';
+import { tmpdir } from 'node:os';
+import { randomUUID } from 'node:crypto';
+import { fileURLToPath } from 'node:url';
+import { dirname } from 'node:path';
+
+const __filename = fileURLToPath(import.meta.url);
+const __dirname = dirname(__filename);
+
+function makeTmpBase(): string {
+  const base = join(tmpdir(), `gsd-test-${randomUUID()}`);
+  mkdirSync(join(base, '.gsd'), { recursive: true });
+  return base;
+}
+
+// ─── register-extension source assertions ────────────────────────────────────
+
+const registerExtSrc = readFileSync(
+  join(__dirname, '..', 'bootstrap', 'register-extension.ts'),
+  'utf-8',
+);
+
+describe('register-extension crash handler secondary fixes (#3348)', () => {
+  test('writeCrashLog is exported and writes a file to the crash directory', async () => {
+    // Dynamic import so GSD_HOME can be pointed at a temp dir without polluting ~/.gsd
+    const tmpHome = join(tmpdir(), `gsd-crash-test-${randomUUID()}`);
+    const origHome = process.env.GSD_HOME;
+    process.env.GSD_HOME = tmpHome;
+    try {
+      const { writeCrashLog } = await import('../bootstrap/crash-log.ts');
+      const err = new Error('test crash from secondary regression test');
+      writeCrashLog(err, 'uncaughtException');
+
+      const crashDir = join(tmpHome, 'crash');
+      assert.ok(existsSync(crashDir), 'crash directory should be created');
+
+      const logs = readdirSync(crashDir).filter((f) => f.endsWith('.log'));
+      assert.equal(logs.length, 1, 'exactly one crash log should be written');
+
+      const content = readFileSync(join(crashDir, logs[0]), 'utf-8');
+      assert.ok(content.includes('test crash from secondary regression test'), 'log should contain error message');
+      assert.ok(content.includes('uncaughtException'), 'log should identify the source');
+      assert.ok(content.includes('pid:'), 'log should include process pid');
+    } finally {
+      process.env.GSD_HOME = origHome;
+      rmSync(tmpHome, { recursive: true, force: true });
+    }
+  });
+
+  test('_gsdRejectionGuard is registered for unhandledRejection', () => {
+    assert.match(
+      registerExtSrc,
+      /_gsdRejectionGuard/,
+      '_gsdRejectionGuard handler should be defined',
+    );
+    assert.match(
+      registerExtSrc,
+      /unhandledRejection/,
+      'installEpipeGuard should register an unhandledRejection handler',
+    );
+  });
+
+  test('_gsdEpipeGuard calls process.exit(1) for unrecoverable errors, not log-and-continue', () => {
+    // The original #3696 fix replaced "throw err" with a log-and-continue.
+    // The secondary fix replaces that with writeCrashLog + process.exit(1).
+    assert.ok(
+      !registerExtSrc.includes('process.stderr.write(`[gsd] uncaught extension error (non-fatal)'),
+      '_gsdEpipeGuard should NOT log errors as non-fatal and continue',
+    );
+    assert.match(
+      registerExtSrc,
+      /process\.exit\(1\)/,
+      '_gsdEpipeGuard should call process.exit(1) for unrecoverable errors',
+    );
+  });
+
+  test('writeCrashLog never throws even when directory is unwritable', async () => {
+    const { writeCrashLog } = await import('../bootstrap/crash-log.ts');
+    const origHome = process.env.GSD_HOME;
+    // Point at a path that will fail to mkdir (e.g. a file that exists as non-dir)
+    const tmpFile = join(tmpdir(), `gsd-not-a-dir-${randomUUID()}`);
+    // Don't create it — mkdirSync with bad path should be caught internally
+    process.env.GSD_HOME = join(tmpFile, 'nested', 'deeply');
+    try {
+      // Should not throw
+      assert.doesNotThrow(() => {
+        writeCrashLog(new Error('should not throw'), 'test');
+      });
+    } finally {
+      process.env.GSD_HOME = origHome;
+    }
+  });
+});
+
+// ─── emitCrashRecoveredUnitEnd ────────────────────────────────────────────────
+
+describe('emitCrashRecoveredUnitEnd (#3348)', () => {
+  test('emits synthetic unit-end when unit-start has no matching unit-end', async () => {
+    const base = makeTmpBase();
+    try {
+      const { emitJournalEvent, queryJournal } = await import('../journal.ts');
+      const { emitCrashRecoveredUnitEnd } = await import('../crash-recovery.ts');
+
+      const flowId = randomUUID();
+      const unitStartSeq = 5;
+
+      // Emit a unit-start with no corresponding unit-end (simulating a crash)
+      emitJournalEvent(base, {
+        ts: new Date().toISOString(),
+        flowId,
+        seq: unitStartSeq,
+        eventType: 'unit-start',
+        data: { unitType: 'execute-task', unitId: 'M001/S01/T01' },
+      });
+
+      const lock = {
+        pid: 99999,
+        startedAt: new Date().toISOString(),
+        unitType: 'execute-task',
+        unitId: 'M001/S01/T01',
+        unitStartedAt: new Date().toISOString(),
+      };
+
+      emitCrashRecoveredUnitEnd(base, lock);
+
+      const events = queryJournal(base);
+      const ends = events.filter((e) => e.eventType === 'unit-end');
+      assert.equal(ends.length, 1, 'should emit exactly one unit-end');
+      assert.equal(ends[0].data?.unitId, 'M001/S01/T01');
+      assert.equal(ends[0].data?.status, 'crash-recovered');
+      assert.equal(ends[0].causedBy?.flowId, flowId);
+      assert.equal(ends[0].causedBy?.seq, unitStartSeq);
+      assert.ok(ends[0].seq > unitStartSeq, 'unit-end seq must be higher than unit-start seq');
+    } finally {
+      rmSync(base, { recursive: true, force: true });
+    }
+  });
+
+  test('is a no-op when unit-end was already emitted (e.g. hard timeout fired)', async () => {
+    const base = makeTmpBase();
+    try {
+      const { emitJournalEvent, queryJournal } = await import('../journal.ts');
+      const { emitCrashRecoveredUnitEnd } = await import('../crash-recovery.ts');
+
+      const flowId = randomUUID();
+      emitJournalEvent(base, {
+        ts: new Date().toISOString(),
+        flowId,
+        seq: 3,
+        eventType: 'unit-start',
+        data: { unitType: 'plan-slice', unitId: 'M001/S02' },
+      });
+      // Hard timeout already emitted a unit-end
+      emitJournalEvent(base, {
+        ts: new Date().toISOString(),
+        flowId,
+        seq: 4,
+        eventType: 'unit-end',
+        data: { unitType: 'plan-slice', unitId: 'M001/S02', status: 'cancelled' },
+        causedBy: { flowId, seq: 3 },
+      });
+
+      const lock = {
+        pid: 99999,
+        startedAt: new Date().toISOString(),
+        unitType: 'plan-slice',
+        unitId: 'M001/S02',
+        unitStartedAt: new Date().toISOString(),
+      };
+      emitCrashRecoveredUnitEnd(base, lock);
+
+      const ends = queryJournal(base).filter((e) => e.eventType === 'unit-end');
+      assert.equal(ends.length, 1, 'should not emit a duplicate unit-end');
+      assert.equal(ends[0].data?.status, 'cancelled', 'original unit-end should be preserved');
+    } finally {
+      rmSync(base, { recursive: true, force: true });
+    }
+  });
+
+  test('is a no-op for "starting" pseudo-units (bootstrap crash)', async () => {
+    const base = makeTmpBase();
+    try {
+      const { queryJournal } = await import('../journal.ts');
+      const { emitCrashRecoveredUnitEnd } = await import('../crash-recovery.ts');
+
+      const lock = {
+        pid: 99999,
+        startedAt: new Date().toISOString(),
+        unitType: 'starting',
+        unitId: 'bootstrap',
+        unitStartedAt: new Date().toISOString(),
+      };
+      emitCrashRecoveredUnitEnd(base, lock);
+
+      const events = queryJournal(base);
+      assert.equal(events.length, 0, 'should emit nothing for starting/bootstrap pseudo-units');
+    } finally {
+      rmSync(base, { recursive: true, force: true });
+    }
+  });
+
+  test('is a no-op when no unit-start exists in the journal', async () => {
+    const base = makeTmpBase();
+    try {
+      const { queryJournal } = await import('../journal.ts');
+      const { emitCrashRecoveredUnitEnd } = await import('../crash-recovery.ts');
+
+      const lock = {
+        pid: 99999,
+        startedAt: new Date().toISOString(),
+        unitType: 'execute-task',
+        unitId: 'M002/S01/T03',
+        unitStartedAt: new Date().toISOString(),
+      };
+      emitCrashRecoveredUnitEnd(base, lock);
+
+      const events = queryJournal(base);
+      assert.equal(events.length, 0, 'should emit nothing when there is no journal entry to close');
+    } finally {
+      rmSync(base, { recursive: true, force: true });
+    }
+  });
+});