fix: prevent zombie processes with proper process lifecycle management (#1306)

* fix: prevent zombie processes with proper process lifecycle management

- Await proc.exited for fire-and-forget spawns in tmux-utils.ts
- Remove competing process.exit() calls from LSP client and skill-mcp-manager
  signal handlers to let background-agent manager coordinate final exit
- Await process exit after kill() in interactive-bash timeout handler
- Await process exit after kill() in LSP client stop() method

These changes ensure spawned processes are properly reaped and prevent
orphan/zombie processes when running with tmux integration.

* fix: address Copilot review comments on process cleanup

- LSP cleanup: use async/sync split with Promise.allSettled for proper subprocess cleanup
- LSP stop(): make idempotent by nulling proc before await to prevent race conditions
- Interactive-bash timeout: use .then()/.catch() pattern instead of async callback to avoid unhandled rejections
- Skill-mcp-manager: use void+catch pattern for fire-and-forget signal handlers

* fix: address remaining Copilot review comments

- interactive-bash: reject timeout immediately, fire-and-forget zombie cleanup
- skill-mcp-manager: update comments to accurately describe signal handling strategy

* fix: address additional Copilot review comments

- LSP stop(): add 5s timeout to prevent indefinite hang on stuck processes
- tmux-utils: log warnings when pane title setting fails (both spawn/replace)
- BackgroundManager: delay process.exit() to next tick via setImmediate to allow other signal handlers to complete cleanup

* fix: address code review findings

- Increase exit delay from setImmediate to 100ms setTimeout to allow async cleanup
- Use asyncCleanup for SIGBREAK on Windows for consistency with SIGINT/SIGTERM
- Add try/catch around stderr read in spawnTmuxPane for consistency with replaceTmuxPane

* fix: address latest Copilot review comments

- LSP stop(): properly clear timeout when proc.exited wins the race
- BackgroundManager: use process.exitCode before delayed exit for cleaner shutdown
- spawnTmuxPane: remove redundant log import, reuse existing one

* fix: address latest Copilot review comments

- LSP stop(): escalate to SIGKILL on timeout, add logging
- tmux spawnTmuxPane/replaceTmuxPane: drain stderr immediately to avoid backpressure

* fix: address latest Copilot review comments

- Add .catch() to asyncCleanup() signal handlers to prevent unhandled rejections
- Await proc.exited after SIGKILL with 1s timeout to confirm termination

* fix: increase exit delay to 6s to accommodate LSP cleanup

LSP cleanup can take up to 5s (timeout) + 1s (SIGKILL wait), so the exit
delay must be at least 6s to ensure child processes are properly reaped.

src/features/background-agent/manager.ts

@@ -1396,7 +1396,10 @@ function registerProcessSignal(
   const listener = () => {
     handler()
     if (exitAfter) {
-      process.exit(0)
+      // Set exitCode and schedule exit after delay to allow other handlers to complete async cleanup
+      // Use 6s delay to accommodate LSP cleanup (5s timeout + 1s SIGKILL wait)
+      process.exitCode = 0
+      setTimeout(() => process.exit(), 6000)
     }
   }
   process.on(signal, listener)

src/features/skill-mcp-manager/manager.ts

@@ -114,23 +114,15 @@ export class SkillMcpManager {
       this.pendingConnections.clear()
     }
 
-    // Note: 'exit' event is synchronous-only in Node.js, so we use 'beforeExit' for async cleanup
-    // However, 'beforeExit' is not emitted on explicit process.exit() calls
-    // Signal handlers are made async to properly await cleanup
+    // Note: Node's 'exit' event is synchronous-only, so we rely on signal handlers for async cleanup.
+    // Signal handlers invoke the async cleanup function and ignore errors so they don't block or throw.
+    // Don't call process.exit() here - let the background-agent manager handle the final process exit.
+    // Use void + catch to trigger async cleanup without awaiting it in the signal handler.
 
-    process.on("SIGINT", async () => {
-      await cleanup()
-      process.exit(0)
-    })
-    process.on("SIGTERM", async () => {
-      await cleanup()
-      process.exit(0)
-    })
+    process.on("SIGINT", () => void cleanup().catch(() => {}))
+    process.on("SIGTERM", () => void cleanup().catch(() => {}))
     if (process.platform === "win32") {
-      process.on("SIGBREAK", async () => {
-        await cleanup()
-        process.exit(0)
-      })
+      process.on("SIGBREAK", () => void cleanup().catch(() => {}))
     }
   }
 

src/shared/tmux/tmux-utils.ts

@@ -139,10 +139,22 @@ export async function spawnTmuxPane(
   }
 
   const title = `omo-subagent-${description.slice(0, 20)}`
-  spawn([tmux, "select-pane", "-t", paneId, "-T", title], {
+  const titleProc = spawn([tmux, "select-pane", "-t", paneId, "-T", title], {
     stdout: "ignore",
-    stderr: "ignore",
+    stderr: "pipe",
   })
+  // Drain stderr immediately to avoid backpressure
+  const stderrPromise = new Response(titleProc.stderr).text().catch(() => "")
+  const titleExitCode = await titleProc.exited
+  if (titleExitCode !== 0) {
+    const titleStderr = await stderrPromise
+    log("[spawnTmuxPane] WARNING: failed to set pane title", {
+      paneId,
+      title,
+      exitCode: titleExitCode,
+      stderr: titleStderr.trim(),
+    })
+  }
 
   return { success: true, paneId }
 }
@@ -217,10 +229,21 @@ export async function replaceTmuxPane(
   }
 
   const title = `omo-subagent-${description.slice(0, 20)}`
-  spawn([tmux, "select-pane", "-t", paneId, "-T", title], {
+  const titleProc = spawn([tmux, "select-pane", "-t", paneId, "-T", title], {
     stdout: "ignore",
-    stderr: "ignore",
+    stderr: "pipe",
   })
+  // Drain stderr immediately to avoid backpressure
+  const stderrPromise = new Response(titleProc.stderr).text().catch(() => "")
+  const titleExitCode = await titleProc.exited
+  if (titleExitCode !== 0) {
+    const titleStderr = await stderrPromise
+    log("[replaceTmuxPane] WARNING: failed to set pane title", {
+      paneId,
+      exitCode: titleExitCode,
+      stderr: titleStderr.trim(),
+    })
+  }
 
   log("[replaceTmuxPane] SUCCESS", { paneId, sessionId })
   return { success: true, paneId }

src/tools/interactive-bash/tools.ts

@@ -96,10 +96,19 @@ The Bash tool can execute these commands directly. Do NOT retry with interactive
 
       const timeoutPromise = new Promise<never>((_, reject) => {
         const id = setTimeout(() => {
-          proc.kill()
-          reject(new Error(`Timeout after ${DEFAULT_TIMEOUT_MS}ms`))
+          const timeoutError = new Error(`Timeout after ${DEFAULT_TIMEOUT_MS}ms`)
+          try {
+            proc.kill()
+            // Fire-and-forget: wait for process exit in background to avoid zombies
+            void proc.exited.catch(() => {})
+          } catch {
+            // Ignore kill errors; we'll still reject with timeoutError below
+          }
+          reject(timeoutError)
         }, DEFAULT_TIMEOUT_MS)
-        proc.exited.then(() => clearTimeout(id))
+        proc.exited
+          .then(() => clearTimeout(id))
+          .catch(() => clearTimeout(id))
       })
 
       // Read stdout and stderr in parallel to avoid race conditions

src/tools/lsp/client.ts

@@ -33,10 +33,12 @@ class LSPServerManager {
   }
 
   private registerProcessCleanup(): void {
-    const cleanup = () => {
+    // Synchronous cleanup for 'exit' event (cannot await)
+    const syncCleanup = () => {
       for (const [, managed] of this.clients) {
         try {
-          managed.client.stop()
+          // Fire-and-forget during sync exit - process is terminating
+          void managed.client.stop().catch(() => {})
         } catch {}
       }
       this.clients.clear()
@@ -46,23 +48,30 @@ class LSPServerManager {
       }
     }
 
-    process.on("exit", cleanup)
+    // Async cleanup for signal handlers - properly await all stops
+    const asyncCleanup = async () => {
+      const stopPromises: Promise<void>[] = []
+      for (const [, managed] of this.clients) {
+        stopPromises.push(managed.client.stop().catch(() => {}))
+      }
+      await Promise.allSettled(stopPromises)
+      this.clients.clear()
+      if (this.cleanupInterval) {
+        clearInterval(this.cleanupInterval)
+        this.cleanupInterval = null
+      }
+    }
 
-    process.on("SIGINT", () => {
-      cleanup()
-      process.exit(0)
-    })
+    process.on("exit", syncCleanup)
 
-    process.on("SIGTERM", () => {
-      cleanup()
-      process.exit(0)
-    })
+    // Don't call process.exit() here - let other handlers complete their cleanup first
+    // The background-agent manager handles the final exit call
+    // Use async handlers to properly await LSP subprocess cleanup
+    process.on("SIGINT", () => void asyncCleanup().catch(() => {}))
+    process.on("SIGTERM", () => void asyncCleanup().catch(() => {}))
 
     if (process.platform === "win32") {
-      process.on("SIGBREAK", () => {
-        cleanup()
-        process.exit(0)
-      })
+      process.on("SIGBREAK", () => void asyncCleanup().catch(() => {}))
     }
   }
 
@@ -532,8 +541,34 @@ export class LSPClient {
       this.connection.dispose()
       this.connection = null
     }
-    this.proc?.kill()
-    this.proc = null
+    const proc = this.proc
+    if (proc) {
+      this.proc = null
+      let exitedBeforeTimeout = false
+      try {
+        proc.kill()
+        // Wait for exit with timeout to prevent indefinite hang
+        let timeoutId: ReturnType<typeof setTimeout> | undefined
+        const timeoutPromise = new Promise<void>((resolve) => {
+          timeoutId = setTimeout(resolve, 5000)
+        })
+        await Promise.race([
+          proc.exited.then(() => { exitedBeforeTimeout = true }).finally(() => timeoutId && clearTimeout(timeoutId)),
+          timeoutPromise,
+        ])
+        if (!exitedBeforeTimeout) {
+          log("[LSPClient] Process did not exit within timeout, escalating to SIGKILL")
+          try {
+            proc.kill("SIGKILL")
+            // Wait briefly for SIGKILL to take effect
+            await Promise.race([
+              proc.exited,
+              new Promise<void>((resolve) => setTimeout(resolve, 1000)),
+            ])
+          } catch {}
+        }
+      } catch {}
+    }
     this.processExited = true
     this.diagnosticsStore.clear()
   }