Tests: fix flaky shard expectations

src/agents/cli-runner.reliability.test.ts

@@ -3,6 +3,7 @@ import {
   createManagedRun,
   enqueueSystemEventMock,
   requestHeartbeatNowMock,
+  EXISTING_CODEX_CONFIG,
   setupCliRunnerTestModule,
   supervisorSpawnMock,
 } from "./cli-runner.test-support.js";
@@ -174,6 +175,7 @@ describe("runCliAgent reliability", () => {
         prompt: "hi",
         provider: "codex-cli",
         model: "gpt-5.4",
+        config: EXISTING_CODEX_CONFIG,
         timeoutMs: 1_000,
         runId: "run-retry-failure",
         cliSessionId: "thread-123",

src/agents/cli-runner.ts

@@ -5,7 +5,7 @@ import { formatErrorMessage } from "../infra/errors.js";
 import { executePreparedCliRun } from "./cli-runner/execute.js";
 import { prepareCliRunContext } from "./cli-runner/prepare.js";
 import type { RunCliAgentParams } from "./cli-runner/types.js";
-import { FailoverError, resolveFailoverStatus } from "./failover-error.js";
+import { FailoverError, isFailoverError, resolveFailoverStatus } from "./failover-error.js";
 import { classifyFailoverReason, isFailoverErrorMessage } from "./pi-embedded-helpers.js";
 import type { EmbeddedPiRunResult } from "./pi-embedded-runner.js";
 
@@ -56,13 +56,10 @@ export async function runCliAgent(params: RunCliAgentParams): Promise<EmbeddedPi
       const effectiveCliSessionId = output.sessionId ?? context.reusableCliSession.sessionId;
       return buildCliRunResult({ output, effectiveCliSessionId });
     } catch (err) {
-      if (err instanceof FailoverError) {
+      if (isFailoverError(err)) {
+        const retryableSessionId = context.reusableCliSession.sessionId ?? params.cliSessionId;
         // Check if this is a session expired error and we have a session to clear
-        if (
-          err.reason === "session_expired" &&
-          context.reusableCliSession.sessionId &&
-          params.sessionKey
-        ) {
+        if (err.reason === "session_expired" && retryableSessionId && params.sessionKey) {
           // Clear the expired session ID from the session entry
           // This requires access to the session store, which we don't have here
           // We'll need to modify the caller to handle this case

src/agents/failover-error.ts

@@ -40,7 +40,15 @@ export class FailoverError extends Error {
 }
 
 export function isFailoverError(err: unknown): err is FailoverError {
-  return err instanceof FailoverError;
+  if (err instanceof FailoverError) {
+    return true;
+  }
+  return Boolean(
+    err &&
+    typeof err === "object" &&
+    (err as { name?: unknown }).name === "FailoverError" &&
+    typeof (err as { reason?: unknown }).reason === "string",
+  );
 }
 
 export function resolveFailoverStatus(reason: FailoverReason): number | undefined {

src/gateway/call.test.ts

@@ -178,6 +178,7 @@ describe("callGateway url resolution", () => {
   const envSnapshot = captureEnv([
     "OPENCLAW_ALLOW_INSECURE_PRIVATE_WS",
     "OPENCLAW_CONFIG_PATH",
+    "OPENCLAW_GATEWAY_PORT",
     "OPENCLAW_GATEWAY_URL",
     "OPENCLAW_GATEWAY_TOKEN",
     "OPENCLAW_STATE_DIR",
@@ -187,6 +188,7 @@ describe("callGateway url resolution", () => {
     envSnapshot.restore();
     delete process.env.OPENCLAW_ALLOW_INSECURE_PRIVATE_WS;
     delete process.env.OPENCLAW_CONFIG_PATH;
+    delete process.env.OPENCLAW_GATEWAY_PORT;
     delete process.env.OPENCLAW_GATEWAY_URL;
     delete process.env.OPENCLAW_GATEWAY_TOKEN;
     delete process.env.OPENCLAW_STATE_DIR;
@@ -612,6 +614,7 @@ describe("buildGatewayConnectionDetails", () => {
       resolveGatewayPort.mockReturnValue(18800);
       __testing.setDepsForTests({
         loadConfig: {} as never,
+        resolveGatewayPort: () => 18789,
       });
 
       const details = buildGatewayConnectionDetails();

src/gateway/gateway-cli-backend.live-helpers.test.ts

@@ -96,7 +96,7 @@ describe("gateway cli backend live helpers", () => {
       clientDisplayName: "vitest-live",
       clientVersion: "dev",
       mode: GATEWAY_CLIENT_MODES.TEST,
-      connectChallengeTimeoutMs: 30_000,
+      connectChallengeTimeoutMs: 45_000,
     });
     expect(gatewayClientState.lastOptions).not.toHaveProperty("requestTimeoutMs");
   });