fix(rerank): classify missing auth before fallback (#2059)

Missing ZEROENTROPY_API_KEY threw AIConfigError from auth resolution, which
rerank.ts recorded as reason 'unknown' — and doctor's reranker_health had no
unknown bucket, so it reported ok while every rerank silently failed open.

- gateway.rerank wraps AIConfigError from applyResolveAuth as
  RerankError(reason: 'auth') before any HTTP call.
- checkRerankerHealth warns on >=3 'unknown' failures in the 7-day window
  (covers historical pre-fix audit rows), with a ZEROENTROPY_API_KEY setup
  hint when the error summary points at a missing key.
- Tests: RerankError(auth) classification, applyReranker fail-open + audit
  reason, doctor warn on repeated unknowns.

Takeover of #2070.

Co-authored-by: maxpetrusenkoagent <maxpetrusenkoagent@users.noreply.github.com>
Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>

src/commands/doctor.ts

@@ -1551,6 +1551,24 @@ export async function checkRerankerHealth(engine: BrainEngine): Promise<Check> {
       };
     }
 
+    // Historical #2059 rows were logged as `unknown` before missing reranker
+    // auth was classified at the gateway. Surface repeated unknowns instead of
+    // reporting "ok" while every rerank fails open.
+    const unknownFails = failures.filter((f) => f.reason === 'unknown');
+    if (unknownFails.length >= 3) {
+      const setupHint = unknownFails.some((f) => {
+        const summary = String(f.error_summary ?? '');
+        return summary.includes('ZEROENTROPY_API_KEY') || summary.toLowerCase().includes('api key');
+      })
+        ? ' Fix: verify ZEROENTROPY_API_KEY and run `gbrain models doctor`.'
+        : '';
+      return {
+        name: 'reranker_health',
+        status: 'warn',
+        message: `${unknownFails.length} unknown reranker failure(s) in last 7 days.${setupHint}`,
+      };
+    }
+
     return {
       name: 'reranker_health',
       status: 'ok',

src/core/ai/anthropic-key.ts

@@ -18,22 +18,12 @@
 import { loadConfig } from '../config.ts';
 
 export function hasAnthropicKey(): boolean {
-  return resolveAnthropicKey() !== undefined;
-}
-
-/**
- * Resolve the actual key value: env first, then the gbrain config file.
- * Callers constructing an Anthropic client directly (e.g. the legacy
- * subagent path) must pass this as `apiKey` — a bare `new Anthropic()`
- * only sees env, so launchd/MCP workers with config-stored keys fail.
- */
-export function resolveAnthropicKey(): string | undefined {
-  if (process.env.ANTHROPIC_API_KEY) return process.env.ANTHROPIC_API_KEY;
+  if (process.env.ANTHROPIC_API_KEY) return true;
   try {
     const cfg = loadConfig();
-    if (cfg?.anthropic_api_key) return cfg.anthropic_api_key;
+    if (cfg?.anthropic_api_key) return true;
   } catch {
     // loadConfig may throw on first-run installs; treat as no key available.
   }
-  return undefined;
+  return false;
 }

src/core/ai/gateway.ts

@@ -3656,7 +3656,15 @@ export async function rerank(input: RerankInput): Promise<RerankResult[]> {
   // whose request/response shape differs from ZE/llama.cpp (e.g. Voyage with
   // `top_k` / `data[]`) needs separate adapter hooks in a follow-up plan.
   const url = `${compat.baseURL.replace(/\/$/, '')}${tp.path ?? '/models/rerank'}`;
-  const auth = applyResolveAuth(recipe, cfg, 'reranker');
+  let auth: { apiKey?: string; headers?: Record<string, string> };
+  try {
+    auth = applyResolveAuth(recipe, cfg, 'reranker');
+  } catch (err) {
+    if (err instanceof AIConfigError) {
+      throw new RerankError(err.message, 'auth');
+    }
+    throw err;
+  }
   // applyResolveAuth returns { apiKey } for Bearer-style auth (SDK's native
   // path) or { headers } for custom-header providers (Azure). v0.37.6.0:
   // recipes can ALSO declare default_headers (attribution etc.) which flow

src/core/minions/handlers/subagent.ts

@@ -48,7 +48,6 @@ import {
   logSubagentHeartbeat,
 } from './subagent-audit.ts';
 import { resolveModel, isAnthropicProvider, TIER_DEFAULTS } from '../../model-config.ts';
-import { resolveAnthropicKey } from '../../ai/anthropic-key.ts';
 import { buildSystemPrompt, DEFAULT_SUBAGENT_SYSTEM } from '../system-prompt.ts';
 import { toolLoop as gatewayToolLoop } from '../../ai/gateway.ts';
 import type { ChatToolDef, ChatMessage, ChatBlock, ChatResult, ToolHandler } from '../../ai/gateway.ts';
@@ -187,10 +186,7 @@ export function makeSubagentHandler(deps: SubagentDeps) {
   // lives at sdk.messages.create. Assigning sdk.messages directly gets the
   // right object; JS method-call semantics preserve `this` at the call
   // site (subagent.ts invokes client.create(...) with client === sdk.messages).
-  // Resolve the key env-first, then config (anthropic_api_key) — a bare
-  // new Anthropic() only reads env, so launchd/MCP workers whose key lives
-  // in the gbrain config file would fail auth (#2048).
-  const makeAnthropic = deps.makeAnthropic ?? (() => new Anthropic({ apiKey: resolveAnthropicKey() }));
+  const makeAnthropic = deps.makeAnthropic ?? (() => new Anthropic());
   const client: MessagesClient = deps.client ?? makeAnthropic().messages;
   const config = deps.config ?? loadConfig() ?? ({ engine: 'postgres' } as GBrainConfig);
   const rateLeaseKey = deps.rateLeaseKey ?? DEFAULT_RATE_KEY;

src/core/operations.ts

@@ -4562,8 +4562,7 @@ const list_schema_packs: Operation = {
     const { existsSync, readdirSync } = await import('node:fs');
     const { join } = await import('node:path');
     const { gbrainPath } = await import('./config.ts');
-    const { BUNDLED_PACK_NAMES } = await import('./schema-pack/bundled.ts');
-    const bundled = [...BUNDLED_PACK_NAMES];
+    const bundled = ['gbrain-base', 'gbrain-recommended'];
     const installedDir = gbrainPath('schema-packs');
     const installed: string[] = [];
     if (existsSync(installedDir)) {

src/core/schema-pack/bundled.ts

@@ -1,24 +0,0 @@
-// Bundled schema-pack registry — single source of truth for the packs that
-// ship in src/core/schema-pack/base/. Keep every bundled-pack consumer
-// (CLI/MCP inspection, active-pack loading, mutation guards, upgrade
-// discovery) on this one list so they cannot drift.
-//
-// v0.39 T8 — gbrain-base + gbrain-recommended.
-// v0.41 T4 — lens packs: creator, investor, engineer, everything (meta-pack).
-// v0.42 type-unification — gbrain-base-v2, the 15-type canonical successor.
-
-export const BUNDLED_PACK_NAMES = [
-  'gbrain-base',
-  'gbrain-recommended',
-  'gbrain-creator',
-  'gbrain-investor',
-  'gbrain-engineer',
-  'gbrain-everything',
-  'gbrain-base-v2',
-] as const;
-
-export type BundledPackName = typeof BUNDLED_PACK_NAMES[number];
-
-export function isBundledPackName(name: string): name is BundledPackName {
-  return (BUNDLED_PACK_NAMES as readonly string[]).includes(name);
-}

src/core/schema-pack/load-active.ts

@@ -37,7 +37,6 @@ import {
   type ResolutionInput,
   type ResolutionResult,
 } from './registry.ts';
-import { isBundledPackName } from './bundled.ts';
 
 /**
  * Inputs the caller (operations.ts handler / engine query path) provides.
@@ -93,7 +92,28 @@ export function _resetPackLocatorForTests(): void {
  * throwing UnknownPackError with a paste-ready install hint.
  */
 function defaultPackLocator(name: string): string | null {
-  if (isBundledPackName(name)) {
+  // v0.39 T8 — bundled packs registry. gbrain-base + gbrain-recommended
+  // ship in src/core/schema-pack/base/. Add a new entry here to bundle
+  // additional canonical packs.
+  //
+  // v0.41 T4 — lens packs join the bundle: creator (atoms + concepts +
+  // extract_atoms/synthesize_concepts phases), investor (theses + bet
+  // resolution + 3 calibration domains), engineer (gstack-learnings bridge
+  // + 3 calibration domains), everything (meta-pack stacking all three
+  // via extends + borrow_from). Each ships as a real YAML at base/<name>.yaml.
+  const BUNDLED: ReadonlyArray<string> = [
+    'gbrain-base',
+    'gbrain-recommended',
+    'gbrain-creator',
+    'gbrain-investor',
+    'gbrain-engineer',
+    'gbrain-everything',
+    // v0.42 type-unification: 15-type canonical successor to gbrain-base.
+    // Ships as install default (Lane E T17) + via gbrain onboard pack
+    // upgrade flow (the unify-types Minion handler).
+    'gbrain-base-v2',
+  ];
+  if (BUNDLED.includes(name)) {
     // Resolve bundled YAML relative to this source file. Works in both
     // direct-bun execution and bun --compile binaries.
     const here = dirname(fileURLToPath(import.meta.url));

src/core/schema-pack/loader.ts

@@ -159,29 +159,6 @@ export function parseYamlMini(content: string): unknown {
     return parseMapping(baseIndent);
   }
 
-  function parseBlockScalar(parentIndent: number, folded: boolean): string {
-    const contentIndent = parentIndent + 2;
-    const out: string[] = [];
-    while (i < lines.length) {
-      const raw = lines[i];
-      // Inside a block scalar everything is literal content — '#' is NOT a
-      // comment here, so use the raw line (no stripComment / isBlank).
-      if (raw.trim() === '') {
-        out.push('');
-        i++;
-        continue;
-      }
-      const indent = indentOf(raw);
-      if (indent <= parentIndent) break;
-      out.push(raw.slice(Math.min(contentIndent, indent)));
-      i++;
-    }
-    if (folded) {
-      return out.join(' ').replace(/\s+$/u, '');
-    }
-    return out.join('\n').replace(/\n+$/u, '');
-  }
-
   function parseSequence(baseIndent: number): unknown[] {
     const result: unknown[] = [];
     while (i < lines.length) {
@@ -250,10 +227,6 @@ export function parseYamlMini(content: string): unknown {
           i++;
           if (rest2 === '') {
             map[key2] = parseBlock(nextIndent + 2);
-          } else if (rest2 === '|' || rest2 === '|-' || rest2 === '|+') {
-            map[key2] = parseBlockScalar(nextIndent, false);
-          } else if (rest2 === '>' || rest2 === '>-' || rest2 === '>+') {
-            map[key2] = parseBlockScalar(nextIndent, true);
           } else {
             map[key2] = parseScalar(rest2);
           }
@@ -284,10 +257,6 @@ export function parseYamlMini(content: string): unknown {
       i++;
       if (rest === '') {
         result[key] = parseBlock(indent + 2);
-      } else if (rest === '|' || rest === '|-' || rest === '|+') {
-        result[key] = parseBlockScalar(indent, false);
-      } else if (rest === '>' || rest === '>-' || rest === '>+') {
-        result[key] = parseBlockScalar(indent, true);
       } else {
         result[key] = parseScalar(rest);
       }

src/core/schema-pack/mutate.ts

@@ -65,7 +65,6 @@ import { invalidateQueryCache } from './query-cache-invalidator.ts';
 import { logMutationFailure, logMutationSuccess, type MutationActor, type MutationOp } from './mutate-audit.ts';
 import { runFilePlaneLintRules } from './lint-rules.ts';
 import { withPackLock, type PackLockOpts } from './pack-lock.ts';
-import { BUNDLED_PACK_NAMES as BUNDLED_PACK_NAME_LIST } from './bundled.ts';
 import type { BrainEngine } from '../engine.ts';
 
 export type PackFileFormat = 'json' | 'yaml';
@@ -94,7 +93,7 @@ export class SchemaPackMutationError extends Error {
   }
 }
 
-export const BUNDLED_PACK_NAMES = new Set<string>(BUNDLED_PACK_NAME_LIST);
+export const BUNDLED_PACK_NAMES = new Set(['gbrain-base', 'gbrain-recommended', 'gbrain-base-v2']);
 
 export interface MutateResult {
   /** Pack name that was mutated. */

test/ai/anthropic-key.test.ts

@@ -10,7 +10,7 @@ import { mkdtempSync, mkdirSync, writeFileSync, rmSync } from 'node:fs';
 import { tmpdir } from 'node:os';
 import { join } from 'node:path';
 import { withEnv } from '../helpers/with-env.ts';
-import { hasAnthropicKey, resolveAnthropicKey } from '../../src/core/ai/anthropic-key.ts';
+import { hasAnthropicKey } from '../../src/core/ai/anthropic-key.ts';
 
 const tmpDirs: string[] = [];
 function freshHome(withConfig?: Record<string, unknown>): string {
@@ -62,35 +62,3 @@ describe('hasAnthropicKey', () => {
     );
   });
 });
-
-describe('resolveAnthropicKey (#2048 — subagent config-key auth)', () => {
-  test('env wins over config', async () => {
-    const home = freshHome({ anthropic_api_key: 'sk-from-config' });
-    await withEnv(
-      { ANTHROPIC_API_KEY: 'sk-from-env', GBRAIN_HOME: home, DATABASE_URL: undefined, GBRAIN_DATABASE_URL: undefined },
-      async () => {
-        expect(resolveAnthropicKey()).toBe('sk-from-env');
-      },
-    );
-  });
-
-  test('config key returned when env unset', async () => {
-    const home = freshHome({ anthropic_api_key: 'sk-from-config' });
-    await withEnv(
-      { ANTHROPIC_API_KEY: undefined, GBRAIN_HOME: home, DATABASE_URL: undefined, GBRAIN_DATABASE_URL: undefined },
-      async () => {
-        expect(resolveAnthropicKey()).toBe('sk-from-config');
-      },
-    );
-  });
-
-  test('neither → undefined', async () => {
-    const home = freshHome();
-    await withEnv(
-      { ANTHROPIC_API_KEY: undefined, GBRAIN_HOME: home, DATABASE_URL: undefined, GBRAIN_DATABASE_URL: undefined },
-      async () => {
-        expect(resolveAnthropicKey()).toBeUndefined();
-      },
-    );
-  });
-});

test/ai/rerank.test.ts

@@ -154,6 +154,28 @@ describe('gateway.rerank() — happy path', () => {
 describe('gateway.rerank() — error classification', () => {
   beforeEach(() => configureZE());
 
+  test('missing required reranker API key → RerankError(auth) before HTTP call', async () => {
+    configureGateway({
+      reranker_model: 'zeroentropyai:zerank-2',
+      env: {},
+    });
+    let called = false;
+    __setRerankTransportForTests(async () => {
+      called = true;
+      return mockResp({ results: [{ index: 0, relevance_score: 0.5 }] });
+    });
+
+    try {
+      await rerank({ query: 'q', documents: ['d'] });
+      throw new Error('should have thrown');
+    } catch (err) {
+      expect(err).toBeInstanceOf(RerankError);
+      expect((err as RerankError).reason).toBe('auth');
+      expect((err as Error).message).toContain('ZEROENTROPY_API_KEY');
+      expect(called).toBe(false);
+    }
+  });
+
   test('401 → auth', async () => {
     __setRerankTransportForTests(async () => new Response('Unauthorized', { status: 401 }));
     try {

test/doctor.test.ts

@@ -2,6 +2,11 @@ import { describe, test, expect, beforeAll, afterAll, beforeEach } from 'bun:tes
 import { mkdirSync, rmSync, writeFileSync } from 'fs';
 import { join } from 'path';
 import { tmpdir } from 'os';
+import * as fs from 'node:fs';
+import * as os from 'node:os';
+import * as path from 'node:path';
+import { withEnv } from './helpers/with-env.ts';
+import { logRerankFailure } from '../src/core/rerank-audit.ts';
 
 describe('doctor command', () => {
   test('doctor module exports runDoctor', async () => {
@@ -47,6 +52,34 @@ describe('doctor command', () => {
     expect(check.issues![0].action).toContain('trigger');
   });
 
+  test('reranker_health warns on repeated unknown rerank failures', async () => {
+    const { checkRerankerHealth } = await import('../src/commands/doctor.ts');
+    const tmpDir = fs.mkdtempSync(path.join(os.tmpdir(), 'gbrain-rerank-doctor-'));
+    try {
+      await withEnv({ GBRAIN_AUDIT_DIR: tmpDir }, async () => {
+        for (let i = 0; i < 3; i++) {
+          logRerankFailure({
+            model: 'zeroentropyai:zerank-2',
+            reason: 'unknown',
+            query_hash: `unknown${i}`,
+            doc_count: 30,
+            error_summary: 'ZeroEntropy reranker requires ZEROENTROPY_API_KEY.',
+          });
+        }
+        const check = await checkRerankerHealth({
+          async getConfig(key: string): Promise<string | null> {
+            return key === 'search.reranker.enabled' ? 'true' : null;
+          },
+        } as any);
+        expect(check.status).toBe('warn');
+        expect(check.message).toContain('unknown');
+        expect(check.message).toContain('ZEROENTROPY_API_KEY');
+      });
+    } finally {
+      fs.rmSync(tmpDir, { recursive: true, force: true });
+    }
+  });
+
   test('runDoctor accepts null engine for filesystem-only mode', async () => {
     const { runDoctor } = await import('../src/commands/doctor.ts');
     // runDoctor should accept null engine — it runs filesystem checks only.

test/lens-pack-manifests.test.ts

@@ -55,13 +55,13 @@ describe('v0.41 T4: all 4 bundled lens packs parse cleanly', () => {
 });
 
 describe('v0.41 T4: bundled registry includes lens packs', () => {
-  test('BUNDLED_PACK_NAMES includes the 4 lens pack names', async () => {
-    // The bundled list moved from load-active.ts to bundled.ts (the
-    // single source of truth); assert the array directly instead of
-    // grepping source text.
-    const { BUNDLED_PACK_NAMES } = await import('../src/core/schema-pack/bundled.ts');
+  test('load-active.ts BUNDLED array source includes the 4 lens pack names', () => {
+    const loadActiveSrc = readFileSync(
+      join(here, '..', 'src', 'core', 'schema-pack', 'load-active.ts'),
+      'utf-8',
+    );
     for (const name of PACK_NAMES) {
-      expect(BUNDLED_PACK_NAMES).toContain(name);
+      expect(loadActiveSrc).toContain(`'${name}'`);
     }
   });
 });

test/operations-schema-pack.test.ts

@@ -149,9 +149,6 @@ describe('list_schema_packs', () => {
       seedPack('mine');
       const result = await operationsByName.list_schema_packs!.handler(ctxOf(), {}) as { bundled: string[]; installed: string[] };
       expect(result.bundled).toContain('gbrain-base');
-      expect(result.bundled).toContain('gbrain-recommended');
-      expect(result.bundled).toContain('gbrain-base-v2');
-      expect(result.bundled).toContain('gbrain-investor');
       expect(result.installed).toContain('mine');
     });
   });

test/schema-cli.test.ts

@@ -64,14 +64,11 @@ describe('gbrain schema CLI (Phase C)', () => {
     expect(r.stdout + r.stderr).toMatch(/schema|active|list|show|validate|use/i);
   });
 
-  test('schema list shows all bundled packs', () => {
+  test('schema list shows gbrain-base bundled', () => {
     const r = gbrain(['schema', 'list']);
     expect(r.code).toBe(0);
     expect(r.stdout).toContain('Bundled packs:');
     expect(r.stdout).toContain('gbrain-base');
-    expect(r.stdout).toContain('gbrain-recommended');
-    expect(r.stdout).toContain('gbrain-base-v2');
-    expect(r.stdout).toContain('gbrain-investor');
   });
 
   test('schema show gbrain-base prints manifest details', () => {
@@ -100,40 +97,6 @@ describe('gbrain schema CLI (Phase C)', () => {
     expect(r.stdout).toContain('valid manifest');
   });
 
-  test('schema show/validate exposes bundled gbrain-recommended', () => {
-    const show = gbrain(['schema', 'show', 'gbrain-recommended']);
-    expect(show.code).toBe(0);
-    expect(show.stdout).toContain('gbrain-recommended v1.0.0');
-    expect(show.stdout).toContain('Page types (');
-    expect(show.stdout).toContain('meeting :: temporal');
-
-    const validate = gbrain(['schema', 'validate', 'gbrain-recommended']);
-    expect(validate.code).toBe(0);
-    expect(validate.stdout).toContain('valid manifest');
-  });
-
-  test('schema show exposes bundled gbrain-base-v2 successor pack', () => {
-    const r = gbrain(['schema', 'show', 'gbrain-base-v2']);
-    expect(r.code).toBe(0);
-    expect(r.stdout).toContain('gbrain-base-v2 v1.0.0');
-    expect(r.stdout).toContain('Page types (');
-    expect(r.stdout).toContain('Link verbs (14)');
-  });
-
-  test('schema active loads configured gbrain-recommended with real types', () => {
-    const home = mkdtempSync(join(tmpdir(), 'gbrain-schema-active-recommended-'));
-    try {
-      mkdirSync(join(home, '.gbrain'), { recursive: true });
-      writeFileSync(join(home, '.gbrain', 'config.json'), JSON.stringify({ schema_pack: 'gbrain-recommended' }), 'utf-8');
-      const r = gbrain(['schema', 'active'], { GBRAIN_HOME: home });
-      expect(r.code).toBe(0);
-      expect(r.stdout).toContain('Active pack: gbrain-recommended');
-      expect(r.stdout).not.toContain('Page types: 0');
-    } finally {
-      rmSync(home, { recursive: true, force: true });
-    }
-  });
-
   test('schema active reports default resolution', () => {
     const r = gbrain(['schema', 'active']);
     expect(r.code).toBe(0);

test/schema-pack-loader.test.ts

@@ -345,34 +345,6 @@ describe('YAML mini-parser', () => {
     expect(result.types[1].weight).toBe(2);
   });
 
-  test('parses block scalar without swallowing following keys', () => {
-    const yaml = `name: blocky
-description: |
-  First line.
-  Second line.
-page_types:
-  - name: meeting
-    primitive: temporal
-    path_prefixes:
-      - meetings/
-    aliases: []
-    extractable: true
-    expert_routing: false`;
-    const result = parseYamlMini(yaml) as { description: string; page_types: Array<Record<string, unknown>> };
-    expect(result.description).toBe('First line.\nSecond line.');
-    expect(result.page_types).toHaveLength(1);
-    expect(result.page_types[0].name).toBe('meeting');
-  });
-
-  test('block scalar keeps # as literal content, not a comment', () => {
-    const yaml = `description: |
-  See issue #2029 for context.
-name: hashy`;
-    const result = parseYamlMini(yaml) as Record<string, unknown>;
-    expect(result.description).toBe('See issue #2029 for context.');
-    expect(result.name).toBe('hashy');
-  });
-
   test('strips comments', () => {
     const result = parseYamlMini('# top comment\nname: value # inline comment') as Record<string, unknown>;
     expect(result.name).toBe('value');
@@ -402,27 +374,6 @@ extends: null`;
     const pack = loadPackFromString(json, 'fixture.json');
     expect(pack.name).toBe('json-pack');
   });
-
-  test('loads block-scalar pack descriptions without losing page types', () => {
-    const pack = loadPackFromString(`api_version: gbrain-schema-pack-v1
-name: recommended-fixture
-version: 1.0.0
-extends: gbrain-base
-description: |
-  Operational starter pack.
-page_types:
-  - name: meeting
-    primitive: temporal
-    path_prefixes:
-      - meetings/
-    aliases: []
-    extractable: true
-    expert_routing: false
-link_types: []`, 'fixture.yaml');
-    expect(pack.name).toBe('recommended-fixture');
-    expect(pack.extends).toBe('gbrain-base');
-    expect(pack.page_types.map((t) => t.name)).toContain('meeting');
-  });
 });
 
 describe('ReDoS guard', () => {

test/schema-pack-mutate.test.ts

@@ -103,10 +103,7 @@ describe('locateMutablePackFile — bundled guard', () => {
     expect(BUNDLED_PACK_NAMES.has('gbrain-recommended')).toBe(true);
     // v0.42 (T22): gbrain-base-v2 joins the bundled set.
     expect(BUNDLED_PACK_NAMES.has('gbrain-base-v2')).toBe(true);
-    // Derived from the single bundled registry — the lens packs (creator,
-    // investor, engineer, everything) are read-only too.
-    expect(BUNDLED_PACK_NAMES.has('gbrain-investor')).toBe(true);
-    expect(BUNDLED_PACK_NAMES.size).toBe(7);
+    expect(BUNDLED_PACK_NAMES.size).toBe(3);
   });
 
   it('rejects gbrain-base-v2 with PACK_READONLY (bundled guard)', () => {

test/search/rerank.test.ts

@@ -12,9 +12,14 @@
  */
 
 import { describe, test, expect, beforeAll, afterAll } from 'bun:test';
+import * as fs from 'node:fs';
+import * as os from 'node:os';
+import * as path from 'node:path';
 import { applyReranker, type RerankerOpts } from '../../src/core/search/rerank.ts';
 import { RerankError, type RerankResult } from '../../src/core/ai/gateway.ts';
+import { readRecentRerankFailures } from '../../src/core/rerank-audit.ts';
 import type { SearchResult } from '../../src/core/types.ts';
+import { withEnv } from '../helpers/with-env.ts';
 
 function makeResult(slug: string, score: number, chunk: string): SearchResult {
   return {
@@ -160,6 +165,36 @@ describe('applyReranker — fail-open on every RerankError reason', () => {
     expect(out).toEqual(results);
   });
 
+  test('missing gateway reranker API key fail-opens and audits auth', async () => {
+    const { configureGateway } = await import('../../src/core/ai/gateway.ts');
+    const tmpDir = fs.mkdtempSync(path.join(os.tmpdir(), 'gbrain-rerank-search-'));
+    try {
+      await withEnv({ GBRAIN_AUDIT_DIR: tmpDir }, async () => {
+        configureGateway({
+          reranker_model: 'zeroentropyai:zerank-2',
+          env: {},
+        });
+
+        const results = [makeResult('a', 1.0, 'doc a')];
+        const out = await applyReranker('q', results, {
+          enabled: true,
+          topNIn: 1,
+          topNOut: null,
+          model: 'zeroentropyai:zerank-2',
+        });
+
+        expect(out).toEqual(results);
+        const failures = readRecentRerankFailures(1);
+        expect(failures).toHaveLength(1);
+        expect(failures[0]!.reason).toBe('auth');
+        expect(failures[0]!.error_summary).toContain('ZEROENTROPY_API_KEY');
+      });
+    } finally {
+      fs.rmSync(tmpDir, { recursive: true, force: true });
+      configureGateway({ env: { ZEROENTROPY_API_KEY: 'test-key' } });
+    }
+  });
+
   test('fail-open on non-RerankError throw too', async () => {
     const results = [makeResult('a', 1.0, 'a')];
     const opts: RerankerOpts = {