fix(fallback): handle timeout aborts

Co-authored-by: Mykyta Bozhenko <21245729+cheeeee@users.noreply.github.com>

CHANGELOG.md

@@ -28,6 +28,7 @@ Docs: https://docs.clawd.bot
 - Exec approvals: enforce allowlist when ask is off; prefer raw command for node approvals/events.
 - Tools: return a companion-app-required message when node exec is requested with no paired node.
 - Streaming: emit assistant deltas for OpenAI-compatible SSE chunks. (#1147) — thanks @alauppe.
+- Model fallback: treat timeout aborts as failover while preserving user aborts. (#1137) — thanks @cheeeee.
 
 ## 2026.1.18-2
 

src/agents/failover-error.ts

@@ -1,5 +1,7 @@
 import { classifyFailoverReason, type FailoverReason } from "./pi-embedded-helpers.js";
 
+const TIMEOUT_HINT_RE = /timeout|timed out|deadline exceeded|context deadline exceeded/i;
+
 export class FailoverError extends Error {
   readonly reason: FailoverReason;
   readonly provider?: string;
@@ -64,6 +66,11 @@ function getStatusCode(err: unknown): number | undefined {
   return undefined;
 }
 
+function getErrorName(err: unknown): string {
+  if (!err || typeof err !== "object") return "";
+  return "name" in err ? String(err.name) : "";
+}
+
 function getErrorCode(err: unknown): string | undefined {
   if (!err || typeof err !== "object") return undefined;
   const candidate = (err as { code?: unknown }).code;
@@ -86,6 +93,22 @@ function getErrorMessage(err: unknown): string {
   return "";
 }
 
+function hasTimeoutHint(err: unknown): boolean {
+  if (!err) return false;
+  if (getErrorName(err) === "TimeoutError") return true;
+  const message = getErrorMessage(err);
+  return Boolean(message && TIMEOUT_HINT_RE.test(message));
+}
+
+export function isTimeoutError(err: unknown): boolean {
+  if (hasTimeoutHint(err)) return true;
+  if (!err || typeof err !== "object") return false;
+  if (getErrorName(err) !== "AbortError") return false;
+  const cause = "cause" in err ? (err as { cause?: unknown }).cause : undefined;
+  const reason = "reason" in err ? (err as { reason?: unknown }).reason : undefined;
+  return hasTimeoutHint(cause) || hasTimeoutHint(reason);
+}
+
 export function resolveFailoverReasonFromError(err: unknown): FailoverReason | null {
   if (isFailoverError(err)) return err.reason;
 
@@ -99,6 +122,7 @@ export function resolveFailoverReasonFromError(err: unknown): FailoverReason | n
   if (["ETIMEDOUT", "ESOCKETTIMEDOUT", "ECONNRESET", "ECONNABORTED"].includes(code)) {
     return "timeout";
   }
+  if (isTimeoutError(err)) return "timeout";
 
   const message = getErrorMessage(err);
   if (!message) return null;

src/agents/model-fallback.test.ts

@@ -281,6 +281,70 @@ describe("runWithModelFallback", () => {
     expect(run.mock.calls[1]?.[1]).toBe("claude-haiku-3-5");
   });
 
+  it("falls back on timeout abort errors", async () => {
+    const cfg = makeCfg();
+    const timeoutCause = Object.assign(new Error("request timed out"), { name: "TimeoutError" });
+    const run = vi
+      .fn()
+      .mockRejectedValueOnce(
+        Object.assign(new Error("aborted"), { name: "AbortError", cause: timeoutCause }),
+      )
+      .mockResolvedValueOnce("ok");
+
+    const result = await runWithModelFallback({
+      cfg,
+      provider: "openai",
+      model: "gpt-4.1-mini",
+      run,
+    });
+
+    expect(result.result).toBe("ok");
+    expect(run).toHaveBeenCalledTimes(2);
+    expect(run.mock.calls[1]?.[0]).toBe("anthropic");
+    expect(run.mock.calls[1]?.[1]).toBe("claude-haiku-3-5");
+  });
+
+  it("falls back on abort errors with timeout reasons", async () => {
+    const cfg = makeCfg();
+    const run = vi
+      .fn()
+      .mockRejectedValueOnce(
+        Object.assign(new Error("aborted"), { name: "AbortError", reason: "deadline exceeded" }),
+      )
+      .mockResolvedValueOnce("ok");
+
+    const result = await runWithModelFallback({
+      cfg,
+      provider: "openai",
+      model: "gpt-4.1-mini",
+      run,
+    });
+
+    expect(result.result).toBe("ok");
+    expect(run).toHaveBeenCalledTimes(2);
+    expect(run.mock.calls[1]?.[0]).toBe("anthropic");
+    expect(run.mock.calls[1]?.[1]).toBe("claude-haiku-3-5");
+  });
+
+  it("does not fall back on user aborts", async () => {
+    const cfg = makeCfg();
+    const run = vi
+      .fn()
+      .mockRejectedValueOnce(Object.assign(new Error("aborted"), { name: "AbortError" }))
+      .mockResolvedValueOnce("ok");
+
+    await expect(
+      runWithModelFallback({
+        cfg,
+        provider: "openai",
+        model: "gpt-4.1-mini",
+        run,
+      }),
+    ).rejects.toThrow("aborted");
+
+    expect(run).toHaveBeenCalledTimes(1);
+  });
+
   it("appends the configured primary as a last fallback", async () => {
     const cfg = makeCfg({
       agents: {

src/agents/model-fallback.ts

@@ -1,6 +1,11 @@
 import type { ClawdbotConfig } from "../config/config.js";
 import { DEFAULT_MODEL, DEFAULT_PROVIDER } from "./defaults.js";
-import { coerceToFailoverError, describeFailoverError, isFailoverError } from "./failover-error.js";
+import {
+  coerceToFailoverError,
+  describeFailoverError,
+  isFailoverError,
+  isTimeoutError,
+} from "./failover-error.js";
 import {
   buildModelAliasIndex,
   modelKey,
@@ -26,6 +31,7 @@ type FallbackAttempt = {
 
 function isAbortError(err: unknown): boolean {
   if (!err || typeof err !== "object") return false;
+  if (isFailoverError(err)) return false;
   const name = "name" in err ? String(err.name) : "";
   if (name === "AbortError") return true;
   const message =
@@ -33,6 +39,10 @@ function isAbortError(err: unknown): boolean {
   return message.includes("aborted");
 }
 
+function shouldRethrowAbort(err: unknown): boolean {
+  return isAbortError(err) && !isTimeoutError(err);
+}
+
 function buildAllowedModelKeys(
   cfg: ClawdbotConfig | undefined,
   defaultProvider: string,
@@ -216,7 +226,7 @@ export async function runWithModelFallback<T>(params: {
         attempts,
       };
     } catch (err) {
-      if (isAbortError(err)) throw err;
+      if (shouldRethrowAbort(err)) throw err;
       const normalized =
         coerceToFailoverError(err, {
           provider: candidate.provider,
@@ -303,7 +313,7 @@ export async function runWithImageModelFallback<T>(params: {
         attempts,
       };
     } catch (err) {
-      if (isAbortError(err)) throw err;
+      if (shouldRethrowAbort(err)) throw err;
       lastError = err;
       attempts.push({
         provider: candidate.provider,

src/agents/pi-embedded-runner/run/attempt.ts

@@ -66,6 +66,7 @@ import { splitSdkTools } from "../tool-split.js";
 import { formatUserTime, resolveUserTimeFormat, resolveUserTimezone } from "../../date-time.js";
 import { describeUnknownError, mapThinkingLevel } from "../utils.js";
 import { resolveSandboxRuntimeStatus } from "../../sandbox/runtime-status.js";
+import { isTimeoutError } from "../../failover-error.js";
 import { getGlobalHookRunner } from "../../../plugins/hook-runner-global.js";
 
 import type { EmbeddedRunAttemptParams, EmbeddedRunAttemptResult } from "./types.js";
@@ -353,25 +354,38 @@ export async function runEmbeddedAttempt(
 
       let aborted = Boolean(params.abortSignal?.aborted);
       let timedOut = false;
-      const abortRun = (isTimeout = false) => {
+      const getAbortReason = (signal: AbortSignal): unknown =>
+        "reason" in signal ? (signal as { reason?: unknown }).reason : undefined;
+      const makeTimeoutAbortReason = (): Error => {
+        const err = new Error("request timed out");
+        err.name = "TimeoutError";
+        return err;
+      };
+      const makeAbortError = (signal: AbortSignal): Error => {
+        const reason = getAbortReason(signal);
+        const err = reason ? new Error("aborted", { cause: reason }) : new Error("aborted");
+        err.name = "AbortError";
+        return err;
+      };
+      const abortRun = (isTimeout = false, reason?: unknown) => {
         aborted = true;
         if (isTimeout) timedOut = true;
-        runAbortController.abort();
+        if (isTimeout) {
+          runAbortController.abort(reason ?? makeTimeoutAbortReason());
+        } else {
+          runAbortController.abort(reason);
+        }
         void activeSession.abort();
       };
       const abortable = <T>(promise: Promise<T>): Promise<T> => {
         const signal = runAbortController.signal;
         if (signal.aborted) {
-          const err = new Error("aborted");
-          (err as { name?: string }).name = "AbortError";
-          return Promise.reject(err);
+          return Promise.reject(makeAbortError(signal));
         }
         return new Promise<T>((resolve, reject) => {
           const onAbort = () => {
-            const err = new Error("aborted");
-            (err as { name?: string }).name = "AbortError";
             signal.removeEventListener("abort", onAbort);
-            reject(err);
+            reject(makeAbortError(signal));
           };
           signal.addEventListener("abort", onAbort, { once: true });
           promise.then(
@@ -448,7 +462,11 @@ export async function runEmbeddedAttempt(
 
       let messagesSnapshot: AgentMessage[] = [];
       let sessionIdUsed = activeSession.sessionId;
-      const onAbort = () => abortRun();
+      const onAbort = () => {
+        const reason = params.abortSignal ? getAbortReason(params.abortSignal) : undefined;
+        const timeout = reason ? isTimeoutError(reason) : false;
+        abortRun(timeout, reason);
+      };
       if (params.abortSignal) {
         if (params.abortSignal.aborted) {
           onAbort();