🤖 fix: resolve race conditions in stream error handling and test flakiness

src/node/services/aiService.ts

@@ -1270,7 +1270,7 @@ export class AIService extends EventEmitter {
   debugTriggerStreamError(
     workspaceId: string,
     errorMessage = "Test-triggered stream error"
-  ): boolean {
+  ): Promise<boolean> {
     return this.streamManager.debugTriggerStreamError(workspaceId, errorMessage);
   }
 

src/node/services/streamManager.ts

@@ -1177,8 +1177,14 @@ export class StreamManager extends EventEmitter {
         },
         parts: streamInfo.parts,
       };
-      // Write error state to disk (fire-and-forget to not block error emission)
-      void this.partialService.writePartial(workspaceId as string, errorPartialMessage);
+      // Wait for any in-flight partial write to complete before writing error state
+      // This prevents race conditions where the error write and a throttled flush
+      // write at the same time, causing inconsistent partial.json state
+      if (streamInfo.partialWritePromise) {
+        await streamInfo.partialWritePromise;
+      }
+      // Write error state to disk - await to ensure consistent state before any resume
+      await this.partialService.writePartial(workspaceId as string, errorPartialMessage);
 
       // Emit error event
       this.emit("error", {
@@ -1685,9 +1691,10 @@ export class StreamManager extends EventEmitter {
    * This method allows integration tests to simulate stream errors without
    * mocking the AI SDK or network layer. It triggers the same error handling
    * path as genuine stream errors by aborting the stream and manually triggering
-   * the error event (since abort alone doesn't throw, it just sets a flag).
+   * the error event (since abort alone doesn't throw, it just sets a flag that
+   * causes the for-await loop to break cleanly).
    */
-  debugTriggerStreamError(workspaceId: string, errorMessage: string): boolean {
+  async debugTriggerStreamError(workspaceId: string, errorMessage: string): Promise<boolean> {
     const typedWorkspaceId = workspaceId as WorkspaceId;
     const streamInfo = this.workspaceStreams.get(typedWorkspaceId);
 
@@ -1699,9 +1706,12 @@ export class StreamManager extends EventEmitter {
       return false;
     }
 
-    // Abort the stream first
+    // Abort the stream first (causes for-await loop to break cleanly)
     streamInfo.abortController.abort(new Error(errorMessage));
 
+    // Mark as error state (same as catch block does)
+    streamInfo.state = StreamState.ERROR;
+
     // Update streamInfo metadata with error (so subsequent flushes preserve it)
     streamInfo.initialMetadata = {
       ...streamInfo.initialMetadata,
@@ -1710,6 +1720,10 @@ export class StreamManager extends EventEmitter {
     };
 
     // Write error state to partial.json (same as real error handling)
+    // Wait for any in-flight partial write to complete first
+    if (streamInfo.partialWritePromise) {
+      await streamInfo.partialWritePromise;
+    }
     const errorPartialMessage: MuxMessage = {
       id: streamInfo.messageId,
       role: "assistant",
@@ -1724,7 +1738,7 @@ export class StreamManager extends EventEmitter {
       },
       parts: streamInfo.parts,
     };
-    void this.partialService.writePartial(workspaceId, errorPartialMessage);
+    await this.partialService.writePartial(workspaceId, errorPartialMessage);
 
     // Emit error event (same as real error handling)
     this.emit("error", {
@@ -1735,6 +1749,9 @@ export class StreamManager extends EventEmitter {
       errorType: "network",
     } as ErrorEvent);
 
+    // Wait for the stream processing to complete (cleanup)
+    await streamInfo.processingPromise;
+
     return true;
   }
 }

src/node/services/workspaceService.ts

@@ -108,7 +108,7 @@ export class WorkspaceService extends EventEmitter {
    * This is used by integration tests to simulate network errors mid-stream.
    * @returns true if an active stream was found and error was triggered
    */
-  debugTriggerStreamError(workspaceId: string, errorMessage?: string): boolean {
+  debugTriggerStreamError(workspaceId: string, errorMessage?: string): Promise<boolean> {
     return this.aiService.debugTriggerStreamError(workspaceId, errorMessage);
   }
 

tests/integration/streamErrorRecovery.test.ts

@@ -87,27 +87,28 @@ function truncateToLastCompleteMarker(text: string, nonce: string): string {
   return text.substring(0, endIndex);
 }
 
-import type { OrpcSource } from "./helpers";
 import type { OrpcTestClient } from "./orpcTestClient";
 
 /**
  * Helper: Resume stream and wait for successful completion
  * Uses StreamCollector for ORPC-native event handling
  */
 async function resumeAndWaitForSuccess(
-  source: OrpcSource,
   workspaceId: string,
   client: OrpcTestClient,
   model: string,
-  timeoutMs = 15000
+  timeoutMs = 15000,
+  options?: {
+    toolPolicy?: Array<{ regex_match: string; action: "enable" | "disable" | "require" }>;
+  }
 ): Promise<void> {
   const collector = createStreamCollector(client, workspaceId);
   collector.start();
 
   try {
     const resumeResult = await client.workspace.resumeStream({
       workspaceId,
-      options: { model },
+      options: { model, toolPolicy: options?.toolPolicy },
     });
 
     if (!resumeResult.success) {
@@ -261,11 +262,19 @@ IMPORTANT: Do not add any other text. Start immediately with ${nonce}-1: one. If
         await new Promise((resolve) => setTimeout(resolve, 500));
 
         // Resume and wait for completion
-        await resumeAndWaitForSuccess(env, workspaceId, client, `${PROVIDER}:${MODEL}`);
+        // Disable all tools (same as original message) so model outputs text, not tool calls
+        await resumeAndWaitForSuccess(workspaceId, client, `${PROVIDER}:${MODEL}`, 15000, {
+          toolPolicy: [{ regex_match: ".*", action: "disable" }],
+        });
+
+        // Small delay to let history update complete after stream-end
+        // stream-end is emitted before updateHistory completes
+        await new Promise((resolve) => setTimeout(resolve, 500));
 
         // Read final assistant message from history
         const history = await readChatHistory(env.tempDir, workspaceId);
         const assistantMessages = history.filter((m) => m.role === "assistant");
+
         const finalText = assistantMessages
           .flatMap((m) => m.parts)
           .filter((p) => p.type === "text")