fix: preserve shell node resolution and tighten CLI version errors

electron/main.ts

@@ -5,6 +5,7 @@ import fs from 'fs';
 import net from 'net';
 import os from 'os';
 import { TerminalManager } from './terminal-manager';
+import { buildExpandedShellPath } from './path-utils';
 
 /**
  * Return a copy of process.env without __NEXT_PRIVATE_* variables.
@@ -321,28 +322,7 @@ function loadUserShellEnv(): Record<string, string> {
  * claude, nvm, homebrew, etc. Shared by the server launcher and install orchestrator.
  */
 function getExpandedShellPath(): string {
-  const home = os.homedir();
-  const shellPath = userShellEnv.PATH || process.env.PATH || '';
-  const sep = path.delimiter;
-
-  if (process.platform === 'win32') {
-    const appData = process.env.APPDATA || path.join(home, 'AppData', 'Roaming');
-    const localAppData = process.env.LOCALAPPDATA || path.join(home, 'AppData', 'Local');
-    const winExtra = [
-      path.join(appData, 'npm'),
-      path.join(localAppData, 'npm'),
-      path.join(home, '.npm-global', 'bin'),
-      path.join(home, '.local', 'bin'),
-      path.join(home, '.claude', 'bin'),
-    ];
-    const allParts = [shellPath, ...winExtra].join(sep).split(sep).filter(Boolean);
-    return [...new Set(allParts)].join(sep);
-  } else {
-    const basePath = `/usr/local/bin:/opt/homebrew/bin:/usr/bin:/bin`;
-    const raw = `${basePath}:${home}/.npm-global/bin:${home}/.local/bin:${home}/.claude/bin:${shellPath}`;
-    const allParts = raw.split(':').filter(Boolean);
-    return [...new Set(allParts)].join(':');
-  }
+  return buildExpandedShellPath({ shellPath: userShellEnv.PATH || process.env.PATH || '' });
 }
 
 function getPort(): Promise<number> {

electron/path-utils.ts

@@ -0,0 +1,48 @@
+import os from 'os';
+import path from 'path';
+
+interface BuildExpandedShellPathOptions {
+  shellPath?: string;
+  home?: string;
+  platform?: NodeJS.Platform;
+}
+
+/**
+ * Build an expanded PATH for child processes.
+ *
+ * Preserve the user's shell PATH first so `#!/usr/bin/env node` scripts keep
+ * using the same Node runtime the user would get in their shell. This avoids
+ * accidentally downgrading tools like Claude Code to an older system Node.
+ */
+export function buildExpandedShellPath(options: BuildExpandedShellPathOptions = {}): string {
+  const home = options.home || os.homedir();
+  const shellPath = options.shellPath || process.env.PATH || '';
+  const platform = options.platform || process.platform;
+  const sep = path.delimiter;
+
+  if (platform === 'win32') {
+    const appData = process.env.APPDATA || path.join(home, 'AppData', 'Roaming');
+    const localAppData = process.env.LOCALAPPDATA || path.join(home, 'AppData', 'Local');
+    const extras = [
+      path.join(appData, 'npm'),
+      path.join(localAppData, 'npm'),
+      path.join(home, '.npm-global', 'bin'),
+      path.join(home, '.local', 'bin'),
+      path.join(home, '.claude', 'bin'),
+    ];
+    const allParts = [shellPath, ...extras].join(sep).split(sep).filter(Boolean);
+    return [...new Set(allParts)].join(sep);
+  }
+
+  const extras = [
+    path.join(home, '.npm-global', 'bin'),
+    path.join(home, '.local', 'bin'),
+    path.join(home, '.claude', 'bin'),
+    '/opt/homebrew/bin',
+    '/usr/local/bin',
+    '/usr/bin',
+    '/bin',
+  ];
+  const allParts = [shellPath, ...extras].join(':').split(':').filter(Boolean);
+  return [...new Set(allParts)].join(':');
+}

src/__tests__/unit/electron-path-and-error-classifier.test.ts

@@ -0,0 +1,40 @@
+import { describe, it } from 'node:test';
+import assert from 'node:assert/strict';
+import { buildExpandedShellPath } from '../../../electron/path-utils';
+import { classifyError } from '../../lib/error-classifier';
+
+describe('buildExpandedShellPath', () => {
+  it('keeps the user shell PATH ahead of system fallback paths on macOS/Linux', () => {
+    const shellPath = '/Users/test/.nvm/versions/node/v22.22.1/bin:/usr/local/bin:/usr/bin';
+    const expanded = buildExpandedShellPath({
+      shellPath,
+      home: '/Users/test',
+      platform: 'darwin',
+    });
+
+    const parts = expanded.split(':');
+    assert.equal(parts[0], '/Users/test/.nvm/versions/node/v22.22.1/bin');
+    assert.ok(parts.indexOf('/usr/local/bin') > parts.indexOf('/Users/test/.nvm/versions/node/v22.22.1/bin'));
+  });
+});
+
+describe('classifyError', () => {
+  it('does not misclassify a generic Node.js version string as CLI_VERSION_TOO_OLD', () => {
+    const result = classifyError({
+      error: new Error('Claude Code process exited with code 1'),
+      stderr: 'Node.js v18.16.0\n    at file:///path/to/cli.js:1:1',
+      providerName: '联通云',
+    });
+
+    assert.equal(result.category, 'PROCESS_CRASH');
+  });
+
+  it('still classifies genuine minimum-version errors as CLI_VERSION_TOO_OLD', () => {
+    const result = classifyError({
+      error: new Error('upgrade required'),
+      stderr: 'Claude Code CLI upgrade required: minimum supported version is 2.2.0',
+    });
+
+    assert.equal(result.category, 'CLI_VERSION_TOO_OLD');
+  });
+});

src/lib/error-classifier.ts

@@ -176,7 +176,14 @@ const ERROR_PATTERNS: ErrorPattern[] = [
   // ── CLI version too old ──
   {
     category: 'CLI_VERSION_TOO_OLD',
-    patterns: ['version', 'upgrade required', 'minimum version'],
+    patterns: [
+      'upgrade required',
+      'minimum supported version',
+      'minimum claude code version',
+      'requires a newer claude code cli',
+      /claude code cli .*too old/i,
+      /minimum version .*claude/i,
+    ],
     userMessage: () => 'Your Claude Code CLI version is too old.',
     actionHint: () => 'Update to the latest version: npm update -g @anthropic-ai/claude-code',
     retryable: false,