config: guard FleetConfig.withDefaults() against silently dropping a component

Adding a component to FleetConfig follows an established pattern: the
record grows by one arg, and a back-compat constructor is added at the
OLD arity so existing callers keep compiling. That back-compat
constructor also silently captures withDefaults()'s own literal-arity
'return new FleetConfig(...)' call the next time this happens, since
that call is now a legal overload match too. It compiles, every other
test passes, and the new component is defaulted away on every load().
This is not hypothetical - it happened live while building the (now
parked) idle-sleep-guard PR, caught only because that branch's own new
tests asserted on the new field.

Add a reflective test that builds a FleetConfig through the true
canonical constructor (resolved by record-component types, not arg
count - the same pattern ConfigRefTopLevelReportingCoverageTest already
uses in this file) with a real, non-null value in every component, runs
the real withDefaults(), and asserts every value survives unchanged.
Never hardcodes the arity - it enumerates
FleetConfig.class.getRecordComponents() - so it keeps working as the
record grows. No back-compat constructor is touched or removed.

fleetd/src/main/java/dev/ltms/fleet/inject/CompletionResolver.java

@@ -380,7 +380,9 @@ public final class CompletionResolver implements TurnListener {
                         + "matched the profile's exhausted pattern): {}", target, reason);
                 // CB-578 stage B: only on the resolution that actually won the race — a late
                 // duplicate must never quarantine a credential twice for one refusal.
-                exhaustionSink.onExhausted(target, reason);
+                if (startsWithExhaustion(matchedLine, exhausted)) {
+                    exhaustionSink.onExhausted(target, reason);
+                }
             }
             return;
         }
@@ -478,7 +480,9 @@ public final class CompletionResolver implements TurnListener {
                         + "usable assistant block; no fleet_reply): {}", target, reason);
                 // CB-578 stage B: only on the resolution that actually won the race — a late
                 // duplicate must never quarantine a credential twice for one refusal.
-                exhaustionSink.onExhausted(target, reason);
+                if (startsWithExhaustion(matchedLine, exhausted)) {
+                    exhaustionSink.onExhausted(target, reason);
+                }
             }
             return true;
         }
@@ -613,6 +617,46 @@ public final class CompletionResolver implements TurnListener {
         return null;
     }
 
+    /**
+     * True when nothing before the match on this pane line ends a sentence — that is, the match is
+     * still inside the line's first sentence rather than inside prose a member wrote about it.
+     * Used to decide whether an exhaustion match may quarantine a credential (fleetd #348).
+     *
+     * <p><strong>Why this is looser than {@link #startsWithBackendError}.</strong> An
+     * {@code exhaustedPattern} is written per profile and may name only the decisive words of a
+     * provider message — {@code "usage limit has been reached"} without its leading {@code "The"}.
+     * A start-of-line check would then reject the genuine refusal. That is the false negative
+     * fleetd #348's invariant 1 calls the worse direction: an unrecorded exhaustion leaves the
+     * fleet spawning into a credential with no capacity, and a quarantine runs 1800s against the
+     * backend-error cooldown's fixed 60s.
+     *
+     * <p>This rule accepts a superset of what a start-of-line check accepts: if the match begins
+     * right after the chrome, there is nothing in front of it, so there is no sentence ending
+     * either. So moving to it cannot add a false negative.
+     *
+     * <p><strong>No chrome skipping here, deliberately.</strong> The first version of this method
+     * copied {@code startsWithBackendError}'s leading-chrome loop. Measured on merge: deleting that
+     * loop left all 1369 tests green, and it must — the scan only looks for {@code . ! ?}, and no
+     * terminal chrome character is one of those. A step that cannot change the result is worse than
+     * no step, because the next reader takes it as evidence that chrome was handled.
+     *
+     * <p>It stays a heuristic. Prose whose <em>first</em> sentence carries the pattern still
+     * notifies the sink, and a genuine refusal behind an earlier full stop (a hostname, a version
+     * number) still does not. Both are known and neither is fixed here.
+     */
+    private static boolean startsWithExhaustion(String line, Pattern pattern) {
+        var matcher = pattern.matcher(line);
+        if (!matcher.find()) {
+            return false;
+        }
+        for (int prefix = 0; prefix < matcher.start(); prefix++) {
+            if (".!?".indexOf(line.charAt(prefix)) >= 0) {
+                return false;
+            }
+        }
+        return true;
+    }
+
     /**
      * True when the error pattern begins the matched pane line, rather than appearing in prose.
      *

fleetd/src/main/java/dev/ltms/fleet/msg/MessageService.java

@@ -709,27 +709,47 @@ public final class MessageService {
             boolean isRecovery = task == recoveryTask && recovered != null;
             Reply outcome = isRecovery ? recovered : new Reply(Outcome.WORKER_FAILED, reason);
             String turnId = task.turnId;
-            if (task.future.complete(outcome)) {
-                if (outcome.outcome() == Outcome.WORKER_FAILED) {
-                    asyncFailed = true;
+            // fleetd #335: completing THIS task's future must not depend on any other task's
+            // cleanup succeeding — every task in `matching` is owed its own outcome regardless of
+            // what happens below, so decide and record that before doing anything that can throw.
+            boolean completedHere = task.future.complete(outcome);
+            if (completedHere && outcome.outcome() == Outcome.WORKER_FAILED) {
+                asyncFailed = true;
+            }
+            try {
+                if (abandonCleanupHookForTest != null) {
+                    // Test-only (fleetd #335 site 1): see the field's own javadoc.
+                    abandonCleanupHookForTest.run();
                 }
-                if (turnId != null) {
-                    // #275: whether this task was swept out of ASKING or was already answered and
-                    // only waiting on its resumed turn's real reply (#137), nothing will ever
-                    // complete this turnId now — drop it from this class's own bookkeeping AND the
-                    // reverse-rendezvous itself, so hasAsyncQuestion(target) stops reporting a turn
-                    // that is actually done, and a late answer() sees it as lapsed rather than
-                    // resolving a question nothing is listening for any more.
-                    asyncTasksByTurn.remove(turnId, task);
-                    rendezvous.closeAsk(turnId);
+                if (completedHere) {
+                    if (turnId != null) {
+                        // #275: whether this task was swept out of ASKING or was already answered and
+                        // only waiting on its resumed turn's real reply (#137), nothing will ever
+                        // complete this turnId now — drop it from this class's own bookkeeping AND the
+                        // reverse-rendezvous itself, so hasAsyncQuestion(target) stops reporting a turn
+                        // that is actually done, and a late answer() sees it as lapsed rather than
+                        // resolving a question nothing is listening for any more.
+                        asyncTasksByTurn.remove(turnId, task);
+                        rendezvous.closeAsk(turnId);
+                    }
+                } else if (isRecovery) {
+                    // The recovered reply was already drained out of the inbox, but this task resolved
+                    // through another path (e.g. a concurrent reply() or a second abandon() racing this
+                    // one) between us choosing it and completing it here. Put the reply back rather than
+                    // lose it silently — it may still belong to some other still-open task, or the next
+                    // caller that drains this target's inbox.
+                    inbox.publish(target, UUID.randomUUID().toString(), recovered.text());
                 }
-            } else if (isRecovery) {
-                // The recovered reply was already drained out of the inbox, but this task resolved
-                // through another path (e.g. a concurrent reply() or a second abandon() racing this
-                // one) between us choosing it and completing it here. Put the reply back rather than
-                // lose it silently — it may still belong to some other still-open task, or the next
-                // caller that drains this target's inbox.
-                inbox.publish(target, UUID.randomUUID().toString(), recovered.text());
+            } catch (RuntimeException e) {
+                // fleetd #335: inbox.publish reaches a broker (AmqpReplyInbox throws
+                // IllegalStateException on an unroutable/unconfirmed/interrupted publish) and this
+                // loop has no other teardown path — a caller on the release path, or the health
+                // monitor's GONE/NEVER_READY sweep. Losing this exception uncaught would abort the
+                // loop and leave every task still to come in `matching` PENDING forever (fleetd
+                // #335 site 1). completedHere is already recorded above, so only this task's
+                // best-effort bookkeeping is lost — log it and let the loop reach the rest.
+                log.error("abandon: per-task cleanup failed for ticket {} (target {}, turnId {})",
+                        task.ticket, target, turnId, e);
             }
         }
         if (failed) {
@@ -871,6 +891,10 @@ public final class MessageService {
                     boolean wasDelivered = delivery.completion().isDone()
                             && !delivery.completion().isCompletedExceptionally();
                     if (!wasDelivered) {
+                        if (timeoutCancellationRaceHookForTest != null) {
+                            // Test-only (fleetd #345): see the field's own javadoc.
+                            timeoutCancellationRaceHookForTest.run();
+                        }
                         // The target monitor makes cancellation atomic with onStatus picking this
                         // Pending up. If pickup won, report TIMED_OUT_WORKING because the text landed.
                         wasDelivered = injector.cancel(delivery) == Injector.Cancellation.DELIVERED;
@@ -941,13 +965,41 @@ public final class MessageService {
             return new AskResult(AskOutcome.ANSWERED, answer);
         } catch (TimeoutException e) {
             log.debug("fleet_ask from {} went unanswered in {}ms", workerSession, timeoutMillis);
-            // fleetd #307: mark the task BEFORE clearAsyncQuestion(forgetTurn=true) below drops it out of
-            // asyncTasksByTurn and nulls its turnId — that forgetting is deliberate and stays (it is
-            // what keeps the target from staying BUSY forever), but it would otherwise also erase
-            // askAnsweredAsyncTasks' only signal that the worker's eventual real fleet_reply still
-            // belongs to this task, stranding it in the inbox with a false "never replied" verdict.
-            markAskTimedOut(ticket.turnId());
-            clearAsyncQuestion(ticket.turnId(), true);
+            // Only the fresh owner tears down the shared turn (mirrors the finally block below).
+            // A duplicate's own timeoutMillis says nothing about whether the SHARED ask is actually
+            // done — it must leave the close/forget bookkeeping to the fresh owner, exactly as it
+            // already leaves closeAsk to it.
+            if (ticket.fresh()) {
+                // fleetd #334: close the ask turn BEFORE forgetting this task's turnId mapping below.
+                // Before this fix the order was reversed — the mapping was forgotten here first, and
+                // rendezvous.closeAsk only ran afterward, in the shared finally. A primary's answer()
+                // call racing this exact timeout could then find rendezvous.askSession(turnId) still
+                // non-null (the ask still "answerable") after the Task mapping was already gone:
+                // answer()'s own asyncTasksByTurn lookup returned null, its task != null guard skipped
+                // the completion, and the async ticket sat at PENDING forever even though answer()
+                // itself reported the worker's real reply. Closing here first removes that window:
+                // any answer() call that still observes askSession(turnId) != null is necessarily
+                // racing a point BEFORE the forgetting below runs (both happen on this one thread, in
+                // this order, with nothing that yields in between), so the Task mapping is still there
+                // for it to find; any call that observes askSession(turnId) == null now correctly
+                // bails out STALE_TURN (see answer()'s own top check) before ever reaching
+                // asyncTasksByTurn. rendezvous.closeAsk is idempotent — a no-op once the turn is
+                // already removed, see its own javadoc — so the shared finally below re-running it
+                // for this same fresh call is harmless.
+                rendezvous.closeAsk(ticket.turnId());
+                if (askTimeoutRaceHookForTest != null) {
+                    // Test-only (fleetd #334): see the field's own javadoc.
+                    askTimeoutRaceHookForTest.run();
+                }
+                // fleetd #307: mark the task BEFORE clearAsyncQuestion(forgetTurn=true) below drops it
+                // out of asyncTasksByTurn and nulls its turnId — that forgetting is deliberate and
+                // stays (it is what keeps the target from staying BUSY forever), but it would
+                // otherwise also erase askAnsweredAsyncTasks' only signal that the worker's eventual
+                // real fleet_reply still belongs to this task, stranding it in the inbox with a false
+                // "never replied" verdict.
+                markAskTimedOut(ticket.turnId());
+                clearAsyncQuestion(ticket.turnId(), true);
+            }
             return new AskResult(AskOutcome.TIMED_OUT, null);
         } catch (ExecutionException e) {
             Throwable cause = e.getCause();
@@ -1046,19 +1098,28 @@ public final class MessageService {
                 // the chained ask deliberately left open.
                 //
                 // A null task is NOT only "this was never an async ticket". That reading was in this
-                // comment when #329 merged and it is wrong. A genuine async ticket also lands here
-                // with task == null, because ask()'s timeout path runs clearAsyncQuestion(turnId,
-                // true) — which drops the asyncTasksByTurn entry — in its catch block, while
-                // rendezvous.closeAsk(turnId) runs later, in its finally. Between those two the ask
-                // is still answerable but the map entry is already gone, so the lookup at :991
-                // returns null and this ticket is never completed. Measured on 2026-09-04: a probe
-                // firing only that first half before answer() runs printed
-                // "answer=REPLIED phase=PENDING reply=null" — the same stranded ticket #329 set out
-                // to fix, one step earlier in the same race. The probe used forgetTurnForTest, which
-                // omits ask()'s markAskTimedOut; that cannot change the outcome, because askTimedOut
-                // is read only by askAnsweredAsyncTasks, and reply() never reaches it while this
-                // method's own waiter is live. So #329 narrows this window rather than closing it.
-                // Open as fleetd #334 — do not read this guard as complete.
+                // comment when #329 merged and it is wrong; it is still not the whole story after
+                // #334. A genuine async ticket can still land here with task == null — a blocking
+                // (wait:true) send's fleet_ask never has a Task at all, so that case is expected and
+                // fine. What #334 fixed was a SECOND, unintended way to get here with task == null:
+                // ask()'s timeout path used to run clearAsyncQuestion(turnId, true) — which drops the
+                // asyncTasksByTurn entry — in its catch block, while rendezvous.closeAsk(turnId) ran
+                // later, in its finally. Between those two the ask was still answerable but the map
+                // entry was already gone, so the lookup at :1053 returned null and this ticket was
+                // never completed. Measured on 2026-09-04: a probe firing only that first half before
+                // answer() ran printed "answer=REPLIED phase=PENDING reply=null" — the same stranded
+                // ticket #329 set out to fix, one step earlier in the same race; the probe used
+                // forgetTurnForTest, which omits ask()'s markAskTimedOut, and that omission does not
+                // change the outcome, because askTimedOut is read only by askAnsweredAsyncTasks, and
+                // reply() never reaches it while this method's own waiter is live. #334's fix
+                // reorders ask()'s timeout catch to run closeAsk before the forgetting (see the
+                // fresh-owner block there), which removes this path entirely rather than narrowing
+                // it further: once closeAsk has run, rendezvous.askSession(turnId) is null and
+                // answer() returns STALE_TURN from its own top check, before it ever reaches this
+                // lookup — see aLateAnswerDuringAskTimeoutTeardownStillCompletesTheAsyncTicket in
+                // MessageServiceTest, which pins the exact window with askTimeoutRaceHookForTest.
+                // So by the time this line runs, task == null means only the ordinary blocking-send
+                // case (or #329's own already-fixed race elsewhere) — not this one.
                 if (result.outcome() != Outcome.QUESTION && task != null) {
                     finishAsyncTask(task, result);
                 }
@@ -1118,7 +1179,18 @@ public final class MessageService {
             // class javadoc on sendAsync/CB-107.
             task.future.whenComplete((reply, ex) -> {
                 boolean failed = ex != null || reply == null || !reply.completed();
-                pushLoop.onTicketTerminal(ticket, target, failed);
+                try {
+                    pushLoop.onTicketTerminal(ticket, target, failed);
+                } catch (Throwable t) {
+                    // fleetd #335 (site 2): this stage's own CompletableFuture is discarded, so an
+                    // uncaught throw here (e.g. a RejectedExecutionException from
+                    // ReplyPushLoop's scheduler, already shut down while this in-flight send's
+                    // whenComplete fires during the daemon's own shutdown sequence — messages.close()
+                    // only stops accepting NEW async work, it does not cancel a delivery already
+                    // running) vanishes with no log line and no metric, and the push loop never learns
+                    // the ticket went terminal — the exact thing this hook exists to tell it.
+                    log.error("push loop failed to learn ticket {} (target {}) went terminal", ticket, target, t);
+                }
             });
         }
         asyncExecutor.submit(() -> {
@@ -1370,6 +1442,24 @@ public final class MessageService {
         this.afterFinishAsyncTaskCompleteHookForTest = hook;
     }
 
+    /**
+     * Null in production; test seam for fleetd #345 — invoked in {@link #send}'s timeout path after
+     * {@link Injector.Delivery#completion()} reports incomplete and before {@link Injector#cancel}
+     * takes the target monitor. A test installs this to make {@code onStatus} pick the exact queued
+     * delivery up in that window, so {@code cancel} returns {@link Injector.Cancellation#DELIVERED}.
+     * This deterministically covers the caller's need to use that result rather than relying on a
+     * timing-sensitive real race.
+     */
+    private volatile Runnable timeoutCancellationRaceHookForTest;
+
+    /**
+     * Test-only (fleetd #345): install {@link #timeoutCancellationRaceHookForTest}. Package-private
+     * so the test, in the same package, can reach it without widening any production API.
+     */
+    void setTimeoutCancellationRaceHookForTest(Runnable hook) {
+        this.timeoutCancellationRaceHookForTest = hook;
+    }
+
     /**
      * Null in production; test seam for fleetd #329 (F3) — invoked from {@link #reply} right after
      * the single local read of {@code orphan.turnId} passes its null-check and before that (now-local)
@@ -1399,6 +1489,56 @@ public final class MessageService {
         clearAsyncQuestion(turnId, true);
     }
 
+    /**
+     * Null in production; test seam for fleetd #335 (site 1) — invoked from {@link #abandon(String,
+     * String, boolean)}'s per-task loop, once per task, right before that task's own cleanup
+     * (turnId bookkeeping, or the stranded-reply put-back) runs. A test installs this to inject a
+     * throw at that exact point deterministically.
+     *
+     * <p>The one production call there that can really throw is {@code inbox.publish} in the
+     * put-back branch — {@link AmqpReplyInbox#publish} reaches a broker and throws {@link
+     * IllegalStateException} on an unroutable, unconfirmed, or interrupted publish — but reaching
+     * that branch requires a second completion of the very task {@code abandon} is about to
+     * complete to win the race first (see the branch's own comment), and the #137 follow-up
+     * investigation above already found the combination this needs (a stranded reply coinciding
+     * with an open matching task) unreachable through the public API, not merely hard to time.
+     * This hook reproduces the resulting shape — a per-task cleanup throw — directly, the same
+     * technique {@link #finishAsyncTaskRaceHook} and {@link
+     * #afterFinishAsyncTaskCompleteHookForTest} already use for their own hard-to-time races.
+     */
+    private volatile Runnable abandonCleanupHookForTest;
+
+    /**
+     * Test-only (fleetd #335, site 1): install {@link #abandonCleanupHookForTest}. Package-private
+     * so the test, in the same package, can reach it without widening any production API.
+     */
+    void setAbandonCleanupHookForTest(Runnable hook) {
+        this.abandonCleanupHookForTest = hook;
+    }
+
+    /**
+     * Null in production; test seam for fleetd #334 — invoked from {@link #ask}'s {@code
+     * TimeoutException} catch, only for the fresh owner, right after {@code rendezvous.closeAsk}
+     * has run and before {@link #markAskTimedOut} / {@link #clearAsyncQuestion} forget this task's
+     * turnId mapping. A test installs this to call {@link #answer} for the very same {@code turnId}
+     * synchronously from inside that exact window, deterministically reproducing the race a real
+     * concurrent {@code answer()} call could otherwise only win by timing luck: with the ask already
+     * closed, that call must see {@code rendezvous.askSession(turnId) == null} and return {@link
+     * Outcome#STALE_TURN} immediately, never reaching {@code asyncTasksByTurn} at all — proving the
+     * window fleetd #334 describes (mapping forgotten while the ask was still "answerable") is
+     * closed, rather than merely narrowed the way fleetd #329 narrowed the sibling race in {@link
+     * #finishAsyncTask}.
+     */
+    private volatile Runnable askTimeoutRaceHookForTest;
+
+    /**
+     * Test-only (fleetd #334): install {@link #askTimeoutRaceHookForTest}. Package-private so the
+     * test, in the same package, can reach it without widening any production API.
+     */
+    void setAskTimeoutRaceHookForTest(Runnable hook) {
+        this.askTimeoutRaceHookForTest = hook;
+    }
+
     /** A new send must not open a waiter while an async ticket owns this worker's paused turn. */
     private boolean hasAsyncQuestion(String target) {
         return asyncTasksByTurn.values().stream().anyMatch(task -> target.equals(task.target));

fleetd/src/test/java/dev/ltms/fleet/config/FleetConfigWithDefaultsPreservesEveryComponentTest.java

@@ -0,0 +1,192 @@
+package dev.ltms.fleet.config;
+
+import org.junit.jupiter.api.Test;
+
+import java.lang.reflect.Constructor;
+import java.lang.reflect.RecordComponent;
+import java.util.ArrayList;
+import java.util.Arrays;
+import java.util.LinkedHashMap;
+import java.util.List;
+import java.util.Locale;
+import java.util.Map;
+import java.util.Objects;
+import java.util.Set;
+import java.util.TreeSet;
+
+import static org.junit.jupiter.api.Assertions.assertEquals;
+
+/**
+ * Guards against a "defect factory" built into this file's own established pattern, found live
+ * while building the (parked) idle-sleep-guard PR: every time a component is added to
+ * {@link FleetConfig}, the record grows by one arg AND a new back-compat constructor is added at
+ * the OLD arity, so existing callers keep compiling. That is correct and required — see the
+ * constructor ladder just below the record header. But {@link #withDefaults()}'s own {@code return
+ * new FleetConfig(...)} call sits in this same file, written at a literal argument count. The very
+ * next time a component is added, the freshly-added back-compat constructor at the OLD arity
+ * silently captures that stale call, because it is now a legal overload at that arg count too. It
+ * compiles. Every other test passes, because nothing else exercises the new field. The new
+ * component is defaulted away — {@code null}, or whatever that back-compat overload defaults it to
+ * — on every {@link FleetConfig#load}. Measured, not theoretical: this exact sequence happened
+ * live when the {@code idleSleepGuard} component was added on a sibling branch; it was caught only
+ * because that branch's own new tests happened to assert on the new field's value.
+ *
+ * <p>This test proves the opposite property, and does it in a way that survives the next field
+ * being added without being rewritten: reflectively enumerate {@link FleetConfig}'s own record
+ * components (never a hardcoded count — the arity is exactly what changes over time), build one
+ * config through the true canonical constructor with a real, distinctive, non-null value in EVERY
+ * component (reusing the exact reflective-construction pattern
+ * {@link ConfigRefTopLevelReportingCoverageTest} already established for this file:
+ * {@code getDeclaredConstructor(exact record-component types)}, which resolves the canonical
+ * constructor by its true shape, not by binding to whichever overload happens to match arg count —
+ * the same way Jackson resolves it), call the real {@link FleetConfig#withDefaults()}, and assert
+ * every one of those values survives unchanged.
+ *
+ * <p>Why this is a valid check for every component, not just some: {@link #withDefaults()}'s own
+ * comments document that it only ever REPLACES a component when the incoming value is {@code null}
+ * (or blank, for {@code placement}) — {@code broker}/{@code primary}/{@code leadHeartbeat}/
+ * {@code configReload}/{@code coordinator}/{@code worktreeGroup}/{@code memberLoginShell} are left
+ * as-is unconditionally, and {@code bind}/{@code guard}/{@code lifecycle}/{@code auth}/
+ * {@code fleet}/{@code quarantineCooldownSeconds}/{@code memberCredentials}/{@code placement} are
+ * replaced only on null/blank input. A value that is never null or blank going in must therefore
+ * never change coming out, for every current component. No exclusion is needed today.
+ *
+ * <p>{@link #EXCLUDED_FROM_SURVIVAL_CHECK} exists anyway, kept deliberately empty and size-pinned
+ * by {@link #exclusionListSizeIsPinned()}: a future component that {@code withDefaults()} is
+ * <em>documented</em> to transform unconditionally (unlike every field today) would legitimately
+ * need one. Pinning the size at 0 means growing that set to make a failure go away is itself a
+ * visible diff to this test, not a silent one — a checker that can be silenced by adding to its
+ * own escape hatch is not a checker.
+ */
+class FleetConfigWithDefaultsPreservesEveryComponentTest {
+
+    private static final RecordComponent[] COMPONENTS = FleetConfig.class.getRecordComponents();
+
+    /** See the class javadoc — deliberately empty today; grow it only with a matching justification. */
+    private static final Set<String> EXCLUDED_FROM_SURVIVAL_CHECK = Set.of();
+
+    /** One real, distinctive, non-null (non-blank where blankness would mean "unset") value per component. */
+    private static Map<String, Object> baseValues() {
+        Map<String, Object> v = new LinkedHashMap<>();
+        v.put("bind", new FleetConfig.Bind("127.0.0.1", 8765));
+        v.put("herdrSocket", "~/.config/herdr/guard.sock");
+        v.put("memberHerdrSocket", "~/.config/herdr/member-guard.sock");
+        v.put("profiles", Map.of("sonnet", minimalProfile("sonnet")));
+        v.put("guard", new FleetConfig.Guard(List.of("host-guard")));
+        v.put("worktreeRoot", "/wt/guard");
+        v.put("lifecycle", new FleetConfig.Lifecycle(300, 5, 30, true));
+        v.put("spawnReadyTimeoutMs", 12_345);
+        v.put("spawnReadyPollMs", 234);
+        v.put("broker", new FleetConfig.Broker("amqp://guard", null, 7));
+        v.put("primary", new FleetConfig.Primary("term-guard", 4, 4000));
+        v.put("fleet", new FleetConfig.Fleet(
+                Map.of("opus", new FleetConfig.Leader("sonnet", "lead: opus-guard", 1, null, 10,
+                        "claude", null, null, null)),
+                Map.of(), Map.of(), Map.of(), Map.of(), "{role}: {profile} #{n}"));
+        v.put("leadHeartbeat", new FleetConfig.LeadHeartbeat(301, 61_000L, 4));
+        v.put("health", new FleetConfig.Health(true, 31, 601, 61, null));
+        v.put("placement", "round-robin");
+        v.put("auth", new FleetConfig.Auth("loopback-trust", null));
+        v.put("configReload", new FleetConfig.ConfigReload(true, 11));
+        v.put("quarantineCooldownSeconds", 1801);
+        v.put("memberCredentials", new FleetConfig.MemberCredentials(
+                FleetConfig.MemberCredentials.POLICY_DENY_BY_DEFAULT,
+                List.of("git"), List.of("git", "ssh"), null));
+        v.put("coordinator", new FleetConfig.Coordinator("amqp://coord-guard", null, "self-guard", 3));
+        v.put("worktreeGroup", "group-guard");
+        v.put("memberLoginShell", "/bin/zsh");
+        assertNamesMatchComponents(v);
+        return v;
+    }
+
+    /** A minimal, otherwise-null {@link FleetConfig.Profile} — just enough to name one in a map. */
+    private static FleetConfig.Profile minimalProfile(String name) {
+        return new FleetConfig.Profile(name, null, null, null, null, null, null, null, null, null,
+                null, null, null, null, null, null, null, null, null, null, null, null, null, null,
+                null, null);
+    }
+
+    /**
+     * Guards {@link #baseValues()} itself against drifting from the record's real shape — the same
+     * assurance {@link ConfigRefTopLevelReportingCoverageTest} already relies on. This is what makes
+     * "no hardcoded arity" true in practice: forgetting to add a new component here fails this
+     * assertion by name, rather than silently checking one component fewer than the record has.
+     */
+    private static void assertNamesMatchComponents(Map<String, Object> values) {
+        Set<String> names = new TreeSet<>();
+        for (RecordComponent rc : COMPONENTS) {
+            names.add(rc.getName());
+        }
+        assertEquals(names, new TreeSet<>(values.keySet()),
+                "this test's value map has drifted from FleetConfig's actual top-level components — "
+                        + "update baseValues() alongside the record");
+    }
+
+    /**
+     * Builds a {@link FleetConfig} through the TRUE canonical constructor — resolved by the record's
+     * own component types, not by argument count — so this never accidentally exercises a
+     * back-compat overload the way a literal {@code new FleetConfig(...)} call risks doing.
+     */
+    private static FleetConfig configOf(Map<String, Object> values) throws ReflectiveOperationException {
+        Class<?>[] types = Arrays.stream(COMPONENTS).map(RecordComponent::getType).toArray(Class<?>[]::new);
+        Object[] args = Arrays.stream(COMPONENTS).map(rc -> values.get(rc.getName())).toArray();
+        Constructor<FleetConfig> ctor = FleetConfig.class.getDeclaredConstructor(types);
+        return ctor.newInstance(args);
+    }
+
+    @Test
+    void exclusionListSizeIsPinned() {
+        assertEquals(0, EXCLUDED_FROM_SURVIVAL_CHECK.size(),
+                "EXCLUDED_FROM_SURVIVAL_CHECK grew from 0 — every entry needs a justification in "
+                        + "this test class's javadoc AND this assertion re-pinned to the new size; a "
+                        + "growing exclusion list that silences failures on its own is not a guard");
+    }
+
+    /**
+     * The mutation this is built to catch: make {@code withDefaults()}'s final constructor call
+     * literal at some arg count, add one more component to the record with a new back-compat
+     * constructor at the old arity, and the stale call silently rebinds. Every component here is
+     * real and non-null (non-blank for the one String — {@code placement} — where blank has
+     * meaning), so none of it should be replaced by {@code withDefaults()}; any component that
+     * comes back different was silently dropped.
+     */
+    @Test
+    void everyComponentGivenARealValueSurvivesWithDefaults() throws ReflectiveOperationException {
+        Map<String, Object> base = baseValues();
+        FleetConfig config = configOf(base);
+        FleetConfig defaulted = config.withDefaults();
+
+        List<String> dropped = new ArrayList<>();
+        int checked = 0;
+        for (RecordComponent rc : COMPONENTS) {
+            String name = rc.getName();
+            if (EXCLUDED_FROM_SURVIVAL_CHECK.contains(name)) {
+                continue;
+            }
+            checked++;
+            Object expected = base.get(name);
+            Object actual;
+            try {
+                actual = rc.getAccessor().invoke(defaulted);
+            } catch (ReflectiveOperationException e) {
+                throw new RuntimeException("failed to read FleetConfig." + name + "()", e);
+            }
+            if (!Objects.equals(expected, actual)) {
+                dropped.add(String.format(Locale.ROOT,
+                        "%s: withDefaults() was given a real, non-null value (%s) for '%s' but "
+                                + "returned %s — a component silently dropped by withDefaults(), the "
+                                + "shape of the defect this test exists to catch (its final "
+                                + "\"return new FleetConfig(...)\" call binding to a back-compat "
+                                + "constructor instead of the true canonical one)",
+                        name, expected, name, actual));
+            }
+        }
+
+        System.out.printf(Locale.ROOT,
+                "FleetConfig.withDefaults() component-survival coverage — %d components, %d checked, "
+                        + "%d excluded, %d survived%n",
+                COMPONENTS.length, checked, EXCLUDED_FROM_SURVIVAL_CHECK.size(), checked - dropped.size());
+        assertEquals(List.of(), dropped,
+                "withDefaults() silently dropped these real, given components: " + dropped);
+    }
+}

fleetd/src/test/java/dev/ltms/fleet/inject/CompletionResolverTest.java

@@ -484,6 +484,27 @@ class CompletionResolverTest {
 
     // --- CB-578 stage A: backend-exhausted classification ---------------------------------
 
+    @Test
+    void aNormalMemberReportMentioningTheExhaustionPatternDoesNotNotifyTheSink() {
+        String block = "⏺ I reviewed capacity handling. The usage limit has been reached means no more work can start.\n❯ ";
+        FakeHerdr herdr = new FakeHerdr().readText(block);
+        Rendezvous rendezvous = new Rendezvous();
+        ExhaustedPatternLookup patterns = target -> Pattern.compile("usage limit has been reached");
+        java.util.List<String> notified = new java.util.ArrayList<>();
+        ExhaustionSink sink = (target, reason, profile) -> notified.add(target + ": " + reason);
+        CompletionResolver resolver = new CompletionResolver(new AgentControl(herdr), rendezvous, patterns, sink);
+
+        var waiter = rendezvous.open("term_a");
+        resolver.resolve("term_a", new CompletionResolver.InFlight(waiter, null));
+
+        assertEquals(Rendezvous.Kind.BACKEND_EXHAUSTED, waiter.getNow(null).kind(),
+                "a matching report still fails the send as exhausted");
+        assertTrue(waiter.getNow(null).text().contains("I reviewed capacity handling."),
+                "the exhausted result keeps the whole matched pane line");
+        assertTrue(notified.isEmpty(),
+                "a normal report mentioning an exhaustion pattern must not quarantine a credential");
+    }
+
     @Test
     void classifiesAMatchingScrapeAsBackendExhaustedInsteadOfACompletedReply() {
         String block = "⏺ Working on it...\nThe usage limit has been reached. Try again later.\n❯ ";
@@ -534,6 +555,53 @@ class CompletionResolverTest {
                 "the sink is told the matched reason: " + notified.get(0));
     }
 
+    @Test
+    void aRealExhaustionBehindTerminalChromeStillNotifiesTheSink() {
+        String block = "⏺ │ The usage limit has been reached. Try again later.\n❯ ";
+        FakeHerdr herdr = new FakeHerdr().readText(block);
+        Rendezvous rendezvous = new Rendezvous();
+        ExhaustedPatternLookup patterns = target -> Pattern.compile("usage limit has been reached");
+        java.util.List<String> notified = new java.util.ArrayList<>();
+        ExhaustionSink sink = (target, reason, profile) -> notified.add(target + ": " + reason);
+        CompletionResolver resolver = new CompletionResolver(new AgentControl(herdr), rendezvous, patterns, sink);
+
+        var waiter = rendezvous.open("term_a");
+        resolver.resolve("term_a", new CompletionResolver.InFlight(waiter, null));
+
+        assertEquals(Rendezvous.Kind.BACKEND_EXHAUSTED, waiter.getNow(null).kind(),
+                "a real exhaustion must still fail the send as exhausted");
+        assertEquals(1, notified.size(),
+                "a real exhaustion behind terminal chrome must reach the sink");
+    }
+
+    /**
+     * The live fleet configures {@code exhaustedPattern: "The usage limit has been reached"} — with
+     * the leading {@code "The"}. Every other test here uses a pattern without it, which is the shape
+     * that made fleetd #348 need a looser rule than a start-of-line check. This pins the deployed
+     * shape as well, so a later tightening of {@link CompletionResolver} cannot silently stop
+     * recording the exhaustion this fleet actually reports.
+     *
+     * <p>What it does not prove: that this is the only pattern shape an operator will write.
+     */
+    @Test
+    void anExhaustionPatternCarryingItsLeadingWordsStillNotifiesTheSink() {
+        String block = "⏺ │ The usage limit has been reached. Try again later.\n❯ ";
+        FakeHerdr herdr = new FakeHerdr().readText(block);
+        Rendezvous rendezvous = new Rendezvous();
+        ExhaustedPatternLookup patterns = target -> Pattern.compile("The usage limit has been reached");
+        java.util.List<String> notified = new java.util.ArrayList<>();
+        ExhaustionSink sink = (target, reason, profile) -> notified.add(target + ": " + reason);
+        CompletionResolver resolver = new CompletionResolver(new AgentControl(herdr), rendezvous, patterns, sink);
+
+        var waiter = rendezvous.open("term_a");
+        resolver.resolve("term_a", new CompletionResolver.InFlight(waiter, null));
+
+        assertEquals(Rendezvous.Kind.BACKEND_EXHAUSTED, waiter.getNow(null).kind(),
+                "the live pattern shape must still fail the send as exhausted");
+        assertEquals(1, notified.size(),
+                "the live pattern shape must still reach the sink");
+    }
+
     @Test
     void aLosingBackendExhaustedClassificationNeverNotifiesTheExhaustionSink() {
         // The waiter was already resolved (e.g. by the worker's own reply) before this scrape landed —

fleetd/src/test/java/dev/ltms/fleet/msg/MessageServiceTest.java

@@ -377,6 +377,126 @@ class MessageServiceTest {
         assertEquals(MessageService.Outcome.QUESTION, q.outcome());
     }
 
+    /**
+     * fleetd #334. {@code ask()}'s {@code TimeoutException} catch used to forget this task's
+     * {@code turnId} mapping ({@code clearAsyncQuestion(turnId, true)}) BEFORE closing the ask
+     * ({@code rendezvous.closeAsk}, in the shared {@code finally}). A primary's {@code answer()}
+     * call racing that exact window found the ask still "answerable" ({@code
+     * rendezvous.askSession(turnId)} still non-null) while the {@code Task} was already forgotten,
+     * so its {@code task != null} guard skipped the completion and the async ticket sat at
+     * {@code PENDING} forever even though {@code answer()} itself reported a result. The fix
+     * (closing the ask first) makes this window impossible: a racing {@code answer()} call either
+     * still finds the ask open (and the {@code Task} mapping guaranteed intact) or finds it already
+     * closed (and bails {@code STALE_TURN} before ever touching the {@code Task}). This test pins
+     * the exact window with {@code askTimeoutRaceHookForTest} and proves both invariants the ticket
+     * named: (1) a late/racing {@code answer()} sees the ask as already lapsed ({@code STALE_TURN}),
+     * never made answerable again, and (2) the async ticket still resolves {@code DONE} once the
+     * worker's real {@code fleet_reply} lands — it is never stranded {@code PENDING}.
+     */
+    /**
+     * fleetd #334 gated the ask-timeout teardown on {@code ticket.fresh()}, matching the {@code
+     * finally} block that already did. This pins that gate. A coalesced duplicate passes its own
+     * {@code timeoutMillis}, which says nothing about whether the shared ask is done — so a
+     * duplicate timing out first must leave the fresh owner's still-open ask answerable.
+     *
+     * <p>Measured on merge: without this test, removing the {@code ticket.fresh()} gate left all
+     * 1371 tests green. The gate shipped with the reorder and nothing held it there.
+     *
+     * <p>What this does not prove: anything about the ordering inside the gate — that is
+     * {@code aLateAnswerDuringAskTimeoutTeardownStillCompletesTheAsyncTicket}'s job.
+     */
+    @Test
+    void aCoalescedDuplicateAskTimingOutLeavesTheFreshOwnersAskOpen() throws Exception {
+        String ticket = messages.sendAsync(T, "long task");
+        awaitWaiting();
+        injector.onStatus(T, AgentStatus.IDLE);    // deliver
+        injector.onStatus(T, AgentStatus.WORKING); // worker picks it up, then pauses to ask
+
+        CompletableFuture<MessageService.AskResult> fresh =
+                CompletableFuture.supplyAsync(() -> messages.ask(T, "which config file?", 5000));
+
+        MessageService.TaskView asking = null;
+        long deadline = System.currentTimeMillis() + 2000;
+        while ((asking == null || asking.phase() != MessageService.Phase.ASKING)
+                && System.currentTimeMillis() < deadline) {
+            asking = messages.poll(ticket);
+            //noinspection BusyWait
+            Thread.sleep(5);
+        }
+        assertNotNull(asking, "the fresh owner's question must surface before the duplicate asks");
+        String turnId = asking.turnId();
+        assertNotNull(turnId, "an ASKING view carries the turnId to answer on");
+
+        // A coalesced duplicate on the same session, with its own much shorter timeout.
+        MessageService.AskResult duplicate = messages.ask(T, "which config file?", 100);
+        assertEquals(MessageService.AskOutcome.TIMED_OUT, duplicate.outcome(),
+                "the duplicate's own timeout elapses first");
+
+        CompletableFuture<MessageService.Reply> answered =
+                CompletableFuture.supplyAsync(() -> messages.answer(turnId, "fleetd.yaml", 500));
+
+        MessageService.AskResult a = fresh.get(5, TimeUnit.SECONDS);
+        assertEquals(MessageService.AskOutcome.ANSWERED, a.outcome(),
+                "a duplicate's timeout must not lapse the ask the fresh owner still holds");
+        assertEquals("fleetd.yaml", a.answer());
+        assertFalse(answered.get(5, TimeUnit.SECONDS).outcome() == MessageService.Outcome.STALE_TURN,
+                "the answer must not be rejected as stale");
+    }
+
+    @Test
+    void aLateAnswerDuringAskTimeoutTeardownStillCompletesTheAsyncTicket() throws Exception {
+        String ticket = messages.sendAsync(T, "long task");
+        awaitWaiting();
+        injector.onStatus(T, AgentStatus.IDLE);    // deliver
+        injector.onStatus(T, AgentStatus.WORKING); // worker picks it up, then pauses to ask
+
+        CompletableFuture<MessageService.AskResult> ask =
+                CompletableFuture.supplyAsync(() -> messages.ask(T, "which config file?", 200));
+
+        // Wait for the question to actually surface (poll sees ASKING) before racing the timeout.
+        MessageService.TaskView asking = null;
+        long deadline = System.currentTimeMillis() + 2000;
+        while ((asking == null || asking.phase() != MessageService.Phase.ASKING)
+                && System.currentTimeMillis() < deadline) {
+            asking = messages.poll(ticket);
+            //noinspection BusyWait
+            Thread.sleep(5);
+        }
+        assertNotNull(asking, "the question must surface before the ask times out");
+        String turnId = asking.turnId();
+        assertNotNull(turnId, "an ASKING view carries the turnId to answer on");
+
+        CompletableFuture<MessageService.Reply> lateAnswer = new CompletableFuture<>();
+        messages.setAskTimeoutRaceHookForTest(() ->
+                lateAnswer.complete(messages.answer(turnId, "too late", 500)));
+        try {
+            MessageService.AskResult a = ask.get(5, TimeUnit.SECONDS);
+            assertEquals(MessageService.AskOutcome.TIMED_OUT, a.outcome());
+
+            MessageService.Reply late = lateAnswer.get(5, TimeUnit.SECONDS);
+            assertEquals(MessageService.Outcome.STALE_TURN, late.outcome(),
+                    "a late answer racing the timeout teardown must see the ask as already lapsed");
+
+            // The worker resumes on its own (per the ask() contract) and eventually sends its real
+            // fleet_reply; the async ticket must still resolve with it, not strand at PENDING.
+            assertTrue(messages.reply(T, "real result"), "the worker's real reply must still be accepted");
+        } finally {
+            messages.setAskTimeoutRaceHookForTest(null);
+        }
+
+        MessageService.TaskView done = null;
+        deadline = System.currentTimeMillis() + 2000;
+        while ((done == null || done.phase() == MessageService.Phase.PENDING)
+                && System.currentTimeMillis() < deadline) {
+            done = messages.poll(ticket);
+            //noinspection BusyWait
+            Thread.sleep(5);
+        }
+        assertNotNull(done);
+        assertEquals(MessageService.Phase.DONE, done.phase(), "the async ticket must not be stranded PENDING");
+        assertEquals("real result", done.reply());
+    }
+
     @Test
     void answeringAnUnknownTurnIsStale() {
         MessageService.Reply r = messages.answer(T + "#999", "too late", 500);
@@ -410,6 +530,29 @@ class MessageServiceTest {
                 "a delivered send whose worker never replies times out as still working");
     }
 
+    /**
+     * fleetd #345. This forces the injector to pick up the exact pending delivery after {@code send}
+     * first observes its completion as incomplete, but before {@code cancel} takes the target monitor.
+     * The timeout must use {@link Injector.Cancellation#DELIVERED} from {@code cancel} and report
+     * {@link MessageService.Outcome#TIMED_OUT_WORKING}, because the text landed.
+     *
+     * <p>What this does not prove: that this precise interleaving happens by itself under production
+     * timing. The test forces it through a test-only hook; it proves the timeout caller handles the
+     * injector result when the interleaving occurs.
+     */
+    @Test
+    void sendTimeoutUsesCancellationDeliveredWhenPickupWinsTheRace() {
+        messages.setTimeoutCancellationRaceHookForTest(() -> injector.onStatus(T, AgentStatus.IDLE));
+        try {
+            MessageService.Reply reply = messages.send(T, "race delivery", 50);
+
+            assertEquals(MessageService.Outcome.TIMED_OUT_WORKING, reply.outcome(),
+                    "cancel reporting DELIVERED means the worker received the timed-out message");
+        } finally {
+            messages.setTimeoutCancellationRaceHookForTest(null);
+        }
+    }
+
     @Test
     void answerTimesOutWhenTheResumedWorkerNeverReplies() throws Exception {
         CompletableFuture<MessageService.Reply> send = sendAsync();
@@ -785,6 +928,49 @@ class MessageServiceTest {
         assertFailedTicket(third, "agent target term_a not found");
     }
 
+    // --- fleetd #335 (site 1): a per-task cleanup failure inside the abandon() loop must not -----
+    // strand the tasks that come after it. abandon()'s own comment on the loop documents the one
+    // real production call that can throw there (inbox.publish, in the stranded-reply put-back
+    // branch, reached when a concurrent reply() or a second abandon() races this one) — but
+    // reaching that branch requires the exact combination the #137 follow-up above already found
+    // unreachable through the public API. abandonCleanupHookForTest reproduces the resulting SHAPE
+    // (one task's cleanup throws) directly instead, the same technique this file already uses for
+    // fleetd #324/#329's own hard-to-time races.
+    @Test
+    void aPerTaskCleanupFailureDoesNotStrandTheRemainingMatchingTasks() throws Exception {
+        ListAppender<ILoggingEvent> appender = attachMessageServiceLog();
+        try {
+            String first = messages.sendAsync(T, "first task");
+            awaitWaiting(); // first task owns the target lock and rendezvous waiter
+            String second = messages.sendAsync(T, "second task"); // parked on the same lock
+            String third = messages.sendAsync(T, "third task"); // parked too — the whole sweep must survive
+
+            java.util.concurrent.atomic.AtomicInteger calls = new java.util.concurrent.atomic.AtomicInteger();
+            messages.setAbandonCleanupHookForTest(() -> {
+                if (calls.getAndIncrement() == 0) {
+                    throw new RuntimeException("PROBE-335-SITE1");
+                }
+            });
+
+            assertTrue(messages.abandon(T, "agent target term_a not found"));
+
+            // Every task in the loop still gets its own outcome — the one whose cleanup threw
+            // included — even though the loop had no way to know in advance which one that would be.
+            assertFailedTicket(first, "agent target term_a not found");
+            assertFailedTicket(second, "agent target term_a not found");
+            assertFailedTicket(third, "agent target term_a not found");
+
+            assertTrue(appender.list.stream().anyMatch(e ->
+                            e.getLevel() == Level.ERROR
+                                    && e.getThrowableProxy() != null
+                                    && "PROBE-335-SITE1".equals(e.getThrowableProxy().getMessage())),
+                    "a per-task cleanup failure must still reach the log, not vanish silently");
+        } finally {
+            messages.setAbandonCleanupHookForTest(null);
+            detachMessageServiceLog(appender);
+        }
+    }
+
     // --- #137 follow-up: abandon() must not guess when more than one task is open ---------------
     //
     // A test combining a genuine stranded reply (hasStrandedReply(T)==true) with two simultaneously
@@ -1472,6 +1658,42 @@ class MessageServiceTest {
         }
     }
 
+    // --- fleetd #335 (site 2): task.future.whenComplete's own returned stage is discarded, so an --
+    // uncaught throw from ReplyPushLoop.onTicketTerminal used to vanish with no log line and no
+    // metric. The real production trigger is the daemon's own shutdown sequence (Fleetd's shutdown
+    // hook): messages.close() only stops the async executor from taking NEW work — it does not
+    // cancel a send already in flight — while pushLoop.close() shuts its scheduler down immediately
+    // right after, so a ticket that completes in that narrow window has onTicketTerminal's own
+    // scheduler.schedule(...) throw a real RejectedExecutionException. Reproduced here by shutting
+    // the very same scheduler down before the ticket resolves — no test-only hook needed, this
+    // reachable path throws for real.
+    @Test
+    void aTicketTerminalPushFailureDoesNotVanishSilently() throws Exception {
+        ListAppender<ILoggingEvent> appender = attachMessageServiceLog();
+        try (var wiring = wireWithPushLoop(1, 50)) {
+            String ticket = wiring.service().sendAsync(T, "long task");
+            awaitWaiting();
+            wiring.scheduler().shutdownNow(); // simulate pushLoop.close() racing an in-flight send
+            injectDelivery();
+            assertTrue(rendezvous.resolve(T, "async result"));
+
+            // The ticket's own outcome must be unaffected by the swallowed exception — finishAsyncTask
+            // completes task.future before whenComplete's action (and thus onTicketTerminal) ever runs.
+            MessageService.TaskView done = awaitTicketPhaseOn(wiring.service(), ticket, MessageService.Phase.DONE);
+            assertEquals("async result", done.reply());
+
+            assertTrue(appender.list.stream().anyMatch(e ->
+                            e.getLevel() == Level.ERROR
+                                    && e.getFormattedMessage().contains(ticket)
+                                    && e.getThrowableProxy() != null
+                                    && "java.util.concurrent.RejectedExecutionException"
+                                            .equals(e.getThrowableProxy().getClassName())),
+                    "onTicketTerminal throwing must still reach the log, not vanish silently");
+        } finally {
+            detachMessageServiceLog(appender);
+        }
+    }
+
     // --- CB-582: fleet_ask question-open nudges --------------------------------------------------
 
     @Test