fix(discord): clear stale heartbeat timers in SafeGatewayPlugin.connect() (#65087)

* fix(discord): clear stale heartbeat timers in SafeGatewayPlugin.connect()

The @buape/carbon@0.15.0 heartbeat setup has a race where stopHeartbeat()
runs before heartbeatInterval is assigned, leaving a stale setInterval with
a closed reconnectCallback. When the stale interval fires ~41s later it
throws an uncaught exception that bypasses the EventEmitter error path and
crashes the gateway process via process.on('uncaughtException').

Add a connect() override in SafeGatewayPlugin that unconditionally clears
both heartbeatInterval and firstHeartbeatTimeout before calling super. The
parent's connect() only calls stopHeartbeat() when isConnecting=false; when
isConnecting=true it returns early without clearing — this override fills
that gap.

Fixes #65009. Related: #64011, #63387, #62038.

* test(discord): assert super.connect() delegation in SafeGatewayPlugin tests

* fix(ci): update raw-fetch allowlist line numbers for gateway-plugin.ts

The connect() override added in the heartbeat fix shifted the two
pre-existing fetch() callsites from lines 370/436 to 387/453.

* docs(changelog): add discord heartbeat crash note

* test(cli): align plugin registry load-context mock

---------

Co-authored-by: Vincent Koc <vincentkoc@ieee.org>

CHANGELOG.md

@@ -41,6 +41,7 @@ Docs: https://docs.openclaw.ai
 - QA/packaging: stop packaged QA helpers from crashing when optional scenario execution config is unavailable, so npm distributions can skip the repo-only scenario pack without breaking completion-cache and startup paths. (#65118) Thanks @EdderTalmor and @vincentkoc.
 - Media/audio transcription: surface the real provider failure when every audio transcription attempt fails, so status output and the CLI stop collapsing those errors into generic skips. (#65096) Thanks @l0cka and @vincentkoc.
 - Memory/wiki: preserve Unicode letters, digits, and combining marks in wiki slugs and contradiction clustering, and cap Unicode filename segments to safe byte lengths so non-ASCII titles stop collapsing or overflowing path limits. (#64742) Thanks @zhouhe-xydt and @vincentkoc.
+- Discord/gateway: clear stale heartbeat timers before reconnecting so zombie gateway callbacks cannot crash the process and drop in-flight replies. (#65009) Thanks @SARAMALI15792 and @vincentkoc.
 
 ## 2026.4.12
 

extensions/discord/src/monitor/gateway-plugin.test.ts

@@ -0,0 +1,115 @@
+import { beforeAll, beforeEach, describe, expect, it, vi } from "vitest";
+
+const { baseConnectSpy, GatewayIntents, GatewayPlugin } = vi.hoisted(() => {
+  const baseConnectSpy = vi.fn<(resume: boolean) => void>();
+
+  const GatewayIntents = {
+    Guilds: 1 << 0,
+    GuildMessages: 1 << 1,
+    MessageContent: 1 << 2,
+    DirectMessages: 1 << 3,
+    GuildMessageReactions: 1 << 4,
+    DirectMessageReactions: 1 << 5,
+    GuildPresences: 1 << 6,
+    GuildMembers: 1 << 7,
+  } as const;
+
+  class GatewayPlugin {
+    options: unknown;
+    gatewayInfo: unknown;
+    heartbeatInterval: ReturnType<typeof setInterval> | undefined = undefined;
+    firstHeartbeatTimeout: ReturnType<typeof setTimeout> | undefined = undefined;
+    isConnecting: boolean = false;
+
+    constructor(options?: unknown) {
+      this.options = options;
+    }
+
+    async registerClient(_client: unknown): Promise<void> {}
+
+    connect(resume = false): void {
+      baseConnectSpy(resume);
+    }
+  }
+
+  return { baseConnectSpy, GatewayIntents, GatewayPlugin };
+});
+
+vi.mock("@buape/carbon/gateway", () => ({ GatewayIntents, GatewayPlugin }));
+
+vi.mock("@buape/carbon/dist/src/plugins/gateway/index.js", () => ({
+  GatewayIntents,
+  GatewayPlugin,
+}));
+
+vi.mock("openclaw/plugin-sdk/proxy-capture", () => ({
+  captureHttpExchange: vi.fn(),
+  captureWsEvent: vi.fn(),
+  resolveEffectiveDebugProxyUrl: () => undefined,
+  resolveDebugProxySettings: () => ({ enabled: false }),
+}));
+
+vi.mock("openclaw/plugin-sdk/runtime-env", () => ({
+  danger: (value: string) => value,
+}));
+
+describe("SafeGatewayPlugin.connect()", () => {
+  let createDiscordGatewayPlugin: typeof import("./gateway-plugin.js").createDiscordGatewayPlugin;
+
+  beforeAll(async () => {
+    ({ createDiscordGatewayPlugin } = await import("./gateway-plugin.js"));
+  });
+
+  beforeEach(() => {
+    baseConnectSpy.mockClear();
+  });
+
+  function createPlugin() {
+    return createDiscordGatewayPlugin({
+      discordConfig: {},
+      runtime: {
+        log: vi.fn(),
+        error: vi.fn(),
+        exit: vi.fn(),
+      },
+    });
+  }
+
+  it("clears stale heartbeatInterval before delegating to super when isConnecting=true", () => {
+    const plugin = createPlugin();
+
+    const staleInterval = setInterval(() => {}, 99_999);
+    try {
+      plugin.heartbeatInterval = staleInterval;
+
+      // isConnecting is private on GatewayPlugin — cast required.
+      (plugin as unknown as { isConnecting: boolean }).isConnecting = true;
+
+      plugin.connect(false);
+
+      expect(plugin.heartbeatInterval).toBeUndefined();
+      expect(baseConnectSpy).toHaveBeenCalledWith(false);
+    } finally {
+      clearInterval(staleInterval);
+    }
+  });
+
+  it("clears stale firstHeartbeatTimeout before delegating to super when isConnecting=true", () => {
+    const plugin = createPlugin();
+
+    const staleTimeout = setTimeout(() => {}, 99_999);
+    try {
+      plugin.firstHeartbeatTimeout = staleTimeout;
+
+      // isConnecting is private on GatewayPlugin — cast required.
+      (plugin as unknown as { isConnecting: boolean }).isConnecting = true;
+
+      plugin.connect(false);
+
+      expect(plugin.firstHeartbeatTimeout).toBeUndefined();
+      expect(baseConnectSpy).toHaveBeenCalledWith(false);
+    } finally {
+      clearTimeout(staleTimeout);
+    }
+  });
+});

extensions/discord/src/monitor/gateway-plugin.ts

@@ -254,6 +254,23 @@ function createGatewayPlugin(params: {
       super(params.options);
     }
 
+    public override connect(resume = false): void {
+      // Guard against stale heartbeat timers from the @buape/carbon
+      // firstHeartbeatTimeout race (openclaw/openclaw#65009, #64011, #63387).
+      // Parent connect() only calls stopHeartbeat() when isConnecting=false.
+      // If isConnecting=true it returns early — leaving a stale setInterval
+      // that fires with a closed reconnectCallback and crashes the process.
+      if (this.heartbeatInterval !== undefined) {
+        clearInterval(this.heartbeatInterval);
+        this.heartbeatInterval = undefined;
+      }
+      if (this.firstHeartbeatTimeout !== undefined) {
+        clearTimeout(this.firstHeartbeatTimeout);
+        this.firstHeartbeatTimeout = undefined;
+      }
+      super.connect(resume);
+    }
+
     override async registerClient(
       client: Parameters<carbonGateway.GatewayPlugin["registerClient"]>[0],
     ) {

scripts/check-no-raw-channel-fetch.mjs

@@ -22,8 +22,8 @@ const allowedRawFetchCallsites = new Set([
   bundledPluginCallsite("browser", "src/browser/test-fetch.ts", 27),
   bundledPluginCallsite("chutes", "models.ts", 535),
   bundledPluginCallsite("chutes", "models.ts", 542),
-  bundledPluginCallsite("discord", "src/monitor/gateway-plugin.ts", 370),
-  bundledPluginCallsite("discord", "src/monitor/gateway-plugin.ts", 436),
+  bundledPluginCallsite("discord", "src/monitor/gateway-plugin.ts", 387),
+  bundledPluginCallsite("discord", "src/monitor/gateway-plugin.ts", 453),
   bundledPluginCallsite("discord", "src/voice-message.ts", 298),
   bundledPluginCallsite("discord", "src/voice-message.ts", 333),
   bundledPluginCallsite("elevenlabs", "speech-provider.ts", 295),

src/cli/plugin-registry.test.ts

@@ -8,6 +8,25 @@ const logger = {
   debug: vi.fn(),
 };
 
+function withActivatedPluginIdsForTest<T extends Record<string, unknown>>(
+  config: T,
+  pluginIds: string[],
+): T & {
+  plugins: {
+    allow: string[];
+    entries: Record<string, { enabled: true }>;
+  };
+} {
+  return {
+    ...config,
+    plugins: {
+      ...(typeof config.plugins === "object" && config.plugins ? config.plugins : {}),
+      allow: pluginIds,
+      entries: Object.fromEntries(pluginIds.map((pluginId) => [pluginId, { enabled: true }])),
+    },
+  };
+}
+
 const mocks = vi.hoisted(() => ({
   loadOpenClawPlugins: vi.fn<typeof import("../plugins/loader.js").loadOpenClawPlugins>(),
   getActivePluginRegistry: vi.fn<typeof import("../plugins/runtime.js").getActivePluginRegistry>(),
@@ -44,6 +63,25 @@ vi.mock("../plugins/runtime/load-context.js", () => ({
   resolvePluginRuntimeLoadContext: (
     ...args: Parameters<typeof mocks.resolvePluginRuntimeLoadContext>
   ) => mocks.resolvePluginRuntimeLoadContext(...args),
+  buildPluginRuntimeLoadOptionsFromValues: (
+    values: {
+      config: unknown;
+      activationSourceConfig: unknown;
+      autoEnabledReasons: Readonly<Record<string, string[]>>;
+      workspaceDir: string | undefined;
+      env: NodeJS.ProcessEnv;
+      logger: typeof logger;
+    },
+    overrides?: Record<string, unknown>,
+  ) => ({
+    config: values.config,
+    activationSourceConfig: values.activationSourceConfig,
+    autoEnabledReasons: values.autoEnabledReasons,
+    workspaceDir: values.workspaceDir,
+    env: values.env,
+    logger: values.logger,
+    ...overrides,
+  }),
   buildPluginRuntimeLoadOptions: (
     context: {
       config: unknown;
@@ -107,16 +145,7 @@ describe("ensurePluginRegistryLoaded", () => {
         },
       },
     };
-    const autoEnabledConfig = {
-      ...baseConfig,
-      plugins: {
-        entries: {
-          "demo-chat": {
-            enabled: true,
-          },
-        },
-      },
-    };
+    const autoEnabledConfig = withActivatedPluginIdsForTest(baseConfig, ["demo-chat"]);
 
     mocks.resolvePluginRuntimeLoadContext.mockReturnValue({
       rawConfig: baseConfig,
@@ -143,7 +172,7 @@ describe("ensurePluginRegistryLoaded", () => {
     expect(mocks.loadOpenClawPlugins).toHaveBeenCalledWith(
       expect.objectContaining({
         config: autoEnabledConfig,
-        activationSourceConfig: baseConfig,
+        activationSourceConfig: autoEnabledConfig,
         autoEnabledReasons: {
           "demo-chat": ["demo-chat configured"],
         },
@@ -230,6 +259,7 @@ describe("ensurePluginRegistryLoaded", () => {
       plugins: { enabled: true },
       channels: { "demo-channel-a": { enabled: true } },
     };
+    const activatedConfig = withActivatedPluginIdsForTest(config, ["demo-channel-a"]);
 
     mocks.resolvePluginRuntimeLoadContext.mockReturnValue({
       rawConfig: config,
@@ -252,7 +282,8 @@ describe("ensurePluginRegistryLoaded", () => {
     expect(mocks.loadOpenClawPlugins).toHaveBeenCalledTimes(1);
     expect(mocks.loadOpenClawPlugins).toHaveBeenCalledWith(
       expect.objectContaining({
-        config,
+        config: activatedConfig,
+        activationSourceConfig: activatedConfig,
         onlyPluginIds: ["demo-channel-a"],
         throwOnLoadError: true,
         workspaceDir: "/tmp/workspace",
@@ -270,6 +301,7 @@ describe("ensurePluginRegistryLoaded", () => {
         },
       },
     };
+    const activatedConfig = withActivatedPluginIdsForTest(config, ["demo-channel-a"]);
 
     mocks.resolvePluginRuntimeLoadContext.mockReturnValue({
       rawConfig: config,
@@ -291,7 +323,8 @@ describe("ensurePluginRegistryLoaded", () => {
     expect(mocks.loadOpenClawPlugins).toHaveBeenCalledTimes(1);
     expect(mocks.loadOpenClawPlugins).toHaveBeenCalledWith(
       expect.objectContaining({
-        config,
+        config: activatedConfig,
+        activationSourceConfig: activatedConfig,
         onlyPluginIds: ["demo-channel-a"],
         throwOnLoadError: true,
         workspaceDir: "/tmp/workspace",