fix(rate-limits): safely surface Codex RPC exits

src/main/rate-limits/codex-fetcher-rpc-exit-diagnostics.test.ts

@@ -82,9 +82,9 @@ describe('Codex RPC exit diagnostics', () => {
       2
     )
 
-    expect(result.error).toBe(
-      "Codex RPC process exited (exit code 2): error: invalid value 'untrusted' for '--ask-for-approval <APPROVAL_POLICY>'"
-    )
+    expect(result.error).toContain('Codex RPC process exited (exit code 2)')
+    expect(result.error).toContain("invalid value 'untrusted'")
+    expect(result.error).toContain("try '--help'")
   })
 
   it('names the exit code when the child says nothing', async () => {
@@ -101,9 +101,7 @@ describe('Codex RPC exit diagnostics', () => {
       1
     )
 
-    expect(result.error).toBe(
-      'ERROR: The ChatGPT access token could not be refreshed; please sign in again.'
-    )
+    expect(result.error).toBe('Your ChatGPT session could not be refreshed. Please sign in again.')
     // The renderer's re-auth warning gates on exactly this predicate;
     // codex-account-auth-warning.test.ts asserts the surfaced string end-to-end.
     expect(isCodexAuthError(result.error)).toBe(true)
@@ -129,4 +127,14 @@ describe('Codex RPC exit diagnostics', () => {
     expect(result.error).not.toContain('sk-aaaa')
     expect(result.error?.length ?? 0).toBeLessThan(500)
   })
+
+  it('keeps the final failure after startup banners', async () => {
+    const result = await runStub(
+      'Welcome to WSL\nLoading shell profile\nERROR: unknown option --obsolete\n',
+      2
+    )
+
+    expect(result.error).toContain('Welcome to WSL')
+    expect(result.error).toContain('ERROR: unknown option --obsolete')
+  })
 })

src/main/rate-limits/codex-fetcher.ts

@@ -25,8 +25,10 @@ import { getCmdExePath, getSpawnArgsForWindows } from '../win32-utils'
 import { cleanupHiddenRateLimitPty, registerHiddenRateLimitPty } from './hidden-pty-cleanup'
 import { parseWslUncPath } from '../../shared/wsl-paths'
 import { extractCodexAuthError, isCodexAuthError } from '../../shared/codex-auth-errors'
-import { stripAnsiControlSequences } from '../../shared/commit-message-agent-output'
-import { sanitizeCrashReportString } from '../../shared/crash-reporting'
+import {
+  excerptAgentFailureOutput,
+  sanitizeAgentFailureDetail
+} from '../../shared/commit-message-agent-output'
 import { redactString } from '../observability/redactor'
 import { buildWslExecArgs, buildWslLoginShellCommand } from '../../shared/wsl-login-shell-command'
 import {
@@ -66,8 +68,6 @@ const BACKEND_TIMEOUT_MS = 10_000
 // Why: redeeming a reset credit is an explicit user action, not a poll — allow more time for a slow backend.
 const REDEEM_BACKEND_TIMEOUT_MS = 30_000
 const MAX_DIAGNOSTIC_OUTPUT_LENGTH = 100_000
-// Why: one surfaced line, not a log dump — the full capture stays in-process.
-const MAX_EXIT_DETAIL_LENGTH = 200
 
 export type FetchCodexRateLimitsOptions = {
   codexHomePath?: string | null
@@ -881,23 +881,21 @@ async function fetchViaRpc(options?: FetchCodexRateLimitsOptions): Promise<Provi
   })
 }
 
-// Why: this string is the whole diagnosis the user gets, and a hardcoded one
-// hid both the exit status and the child's own auth complaint — so an
-// app-server that quit on a dead refresh token never classified as
-// re-authenticable and never prompted sign-in (worst on Windows, which has no
-// PTY fallback to recover the reason).
+// Why: surfaced text drives re-auth classification, so diagnosis and classification must use the same sanitized value.
 function describeCodexRpcExit(
   code: number | null,
   signal: NodeJS.Signals | null,
   stderr: string
 ): string {
-  const authError = extractCodexAuthError(stderr)
-  if (authError) {
-    return redactCodexChildOutput(authError)
+  if (extractCodexAuthError(stderr)) {
+    // Fixed copy cannot leak paths/tokens and is exactly what the renderer classifies.
+    return 'Your ChatGPT session could not be refreshed. Please sign in again.'
   }
   const reason =
     code !== null ? `exit code ${code}` : signal ? `signal ${signal}` : 'no exit status'
-  const detail = firstReportedStderrLine(stderr)
+  const detail = sanitizeAgentFailureDetail(
+    redactString(excerptAgentFailureOutput('', stderr) ?? '')
+  )
   return withMacTailscaleDnsHint(
     detail
       ? `Codex RPC process exited (${reason}): ${detail}`
@@ -906,28 +904,6 @@ function describeCodexRpcExit(
   )
 }
 
-function firstReportedStderrLine(stderr: string): string | null {
-  for (const rawLine of stripAnsiControlSequences(stderr).split(/\r\n|\n|\r/)) {
-    const line = rawLine.trim()
-    if (line) {
-      return redactCodexChildOutput(line)
-    }
-  }
-  return null
-}
-
-// Why: redactString kills token shapes without eating prose, while the
-// crash-report pass adds path scrubbing but is greedy enough to swallow the
-// rest of a line — so it is dropped when it would erase the auth phrase the
-// re-auth warning classifies on.
-function redactCodexChildOutput(text: string): string {
-  const withoutSecrets = redactString(text)
-  const withoutPaths = sanitizeCrashReportString(withoutSecrets, MAX_EXIT_DETAIL_LENGTH)
-  return isCodexAuthError(withoutSecrets) && !isCodexAuthError(withoutPaths)
-    ? withoutSecrets.slice(0, MAX_EXIT_DETAIL_LENGTH)
-    : withoutPaths
-}
-
 // ---------------------------------------------------------------------------
 // PTY fallback — spawn `codex`, send `/status`, parse rendered output
 // ---------------------------------------------------------------------------

src/main/text-generation/commit-message-text-generation.ts

@@ -19,7 +19,8 @@ import {
 } from '../../shared/pull-request-generation'
 import {
   cleanGeneratedCommitMessage,
-  excerptAgentFailureOutput
+  excerptAgentFailureOutput,
+  sanitizeAgentFailureDetail
 } from '../../shared/commit-message-prompt'
 import {
   captureAgentGenerationFailureOutput,
@@ -196,40 +197,6 @@ function formatAgentCliFailureMessage(
     : withMacTailscaleDnsHint(message, detail)
 }
 
-function sanitizeAgentFailureDetail(detail: string | null): string | null {
-  // Cf covers bidi overrides (U+202E etc.) that could visually reorder the
-  // persisted, client-synced detail.
-  const trimmed = detail
-    ?.replace(/[\p{Cc}\p{Cf}]+/gu, ' ')
-    .replace(/\s+/g, ' ')
-    .trim()
-  if (!trimmed) {
-    return null
-  }
-  // Why: agent stderr often includes local or SSH repo paths. Persisting those
-  // into worktree metadata leaks environment details into synced renderer state.
-  const redacted = trimmed
-    .replace(
-      /\\\\[^\s"'`<>\\]+\\(?:[^\s"'`<>\\]+(?:\s+[^\s"'`<>\\]+)*(?=\\)\\)*[^\s"'`<>\\]+/g,
-      '[path]'
-    )
-    // Only backslashes may repeat: JSON provider bodies double them
-    // (`C:\\Users\\name\\…`), while a URL's `://` must stay single so remedy
-    // links like `https://…` survive redaction.
-    .replace(
-      /[A-Za-z]:(?:\\+|\/)(?:[^\s"'`<>\\/|:*?]+(?:\s+[^\s"'`<>\\/|:*?]+)*(?=[\\/])(?:\\+|\/))*[^\s"'`<>\\/|:*?]+/g,
-      '[path]'
-    )
-    // Why: require ≥2 segments (one internal `/`) so provider remedy tokens like
-    // `/login` survive while multi-segment paths (`/Users/name/repo`) still redact.
-    // `=:,` prefixes catch key=/path value:/path list,/path shapes in provider bodies.
-    .replace(
-      /(^|[\s"'`(=:,])\/(?:[^\s"'`<>/]+(?:\s+[^\s"'`<>/]+)*(?=\/)\/)+[^\s"'`<>/]+/g,
-      '$1[path]'
-    )
-  return redacted.length > 240 ? `${redacted.slice(0, 240).trimEnd()}...` : redacted
-}
-
 function userFacingUnsafeWindowsBatchArgs(label: string): string {
   return `${label} cannot be run as a Windows batch command with the prompt in argv. Remove {prompt} so Orca sends the prompt on stdin.`
 }

src/renderer/src/components/settings/codex-account-auth-warning.test.ts

@@ -38,14 +38,10 @@ describe('codex account auth warning', () => {
     ).toBe(false)
   })
 
-  // Strings produced verbatim by the RPC-exit path in
-  // codex-fetcher-rpc-exit-diagnostics.test.ts.
   it('warns re-auth when the app-server quits over a dead refresh token', () => {
     expect(
       getCodexAccountAuthWarning({
-        limits: codexLimits(
-          'ERROR: The ChatGPT access token could not be refreshed; please sign in again.'
-        ),
+        limits: codexLimits('Your ChatGPT session could not be refreshed. Please sign in again.'),
         target: { runtime: 'host', wslDistro: null },
         runtime: { runtime: 'host' },
         activeAccountId: 'account-1',

src/shared/commit-message-agent-output.ts

@@ -158,6 +158,33 @@ export function excerptAgentFailureOutput(stdout: string, stderr: string): strin
   return composeTwoEndExcerpt(headLines, tailLine)
 }
 
+export function sanitizeAgentFailureDetail(detail: string | null): string | null {
+  // Cf covers bidi overrides that could visually reorder persisted, client-synced text.
+  const trimmed = detail
+    ?.replace(/[\p{Cc}\p{Cf}]+/gu, ' ')
+    .replace(/\s+/g, ' ')
+    .trim()
+  if (!trimmed) {
+    return null
+  }
+  const redacted = trimmed
+    .replace(
+      /\\\\[^\s"'`<>\\]+\\(?:[^\s"'`<>\\]+(?:\s+[^\s"'`<>\\]+)*(?=\\)\\)*[^\s"'`<>\\]+/g,
+      '[path]'
+    )
+    // JSON may double Windows separators; URL separators must remain single.
+    .replace(
+      /[A-Za-z]:(?:\\+|\/)(?:[^\s"'`<>\\/|:*?]+(?:\s+[^\s"'`<>\\/|:*?]+)*(?=[\\/])(?:\\+|\/))*[^\s"'`<>\\/|:*?]+/g,
+      '[path]'
+    )
+    // Keep single-segment remedies such as /login while redacting filesystem paths.
+    .replace(
+      /(^|[\s"'`(=:,])\/(?:[^\s"'`<>/]+(?:\s+[^\s"'`<>/]+)*(?=\/)\/)+[^\s"'`<>/]+/g,
+      '$1[path]'
+    )
+  return redacted.length > 240 ? `${redacted.slice(0, 240).trimEnd()}...` : redacted
+}
+
 function composeTwoEndExcerpt(headLines: string[], tailLine: string | null): string {
   const headPart = truncateExcerptPart(headLines.join(' '), FAILURE_EXCERPT_HEAD_BUDGET)
   // Repeated lines (spinner/retry frames) would otherwise show twice.

src/shared/commit-message-prompt.ts

@@ -19,7 +19,8 @@ Staged diff:
 
 export {
   cleanGeneratedCommitMessage,
-  excerptAgentFailureOutput
+  excerptAgentFailureOutput,
+  sanitizeAgentFailureDetail
 } from './commit-message-agent-output'
 
 /** Builds the final prompt sent to the agent. The custom suffix is appended verbatim