fix(routes): never mask the launch error during cleanup

_cleanup_chat_start_launch_failure runs inside the launch-failure handler,
but the session re-resolve only caught KeyError. An unreadable or
undeserializable session store raises something else, and that escaped the
helper, replacing the worker-launch error the caller is about to report and
aborting the reset after the registries were already cleared.

Contain the resolution-and-reset so the helper cannot raise. The KeyError
branch keeps its meaning (deleted session, return without saving); anything
else is logged at debug like the existing save() failure path.

api/routes.py

@@ -22824,6 +22824,12 @@ def _cleanup_chat_start_launch_failure(session, stream_id: str) -> None:
     # could resurrect a session deleted while the launch was failing. Same
     # pattern as the #1533 race fix (routes.py:3077) and the anchor-scene
     # write guard (routes.py:5140).
+    #
+    # This runs while the original launch failure is being handled, so it must
+    # never raise. Lock acquisition and session resolution can fail on their own
+    # (I/O, deserialization), and an escaping error here would mask the launch
+    # failure the caller is about to report while leaving the reset half done.
+    try:
         with _get_session_agent_lock(session.session_id):
             try:
                 canonical = get_session(session.session_id)
@@ -22844,6 +22850,12 @@ def _cleanup_chat_start_launch_failure(session, stream_id: str) -> None:
                     stream_id,
                     exc_info=True,
                 )
+    except Exception:
+        logger.debug(
+            "Failed to reset session state after worker launch failure for %s",
+            stream_id,
+            exc_info=True,
+        )
 
 
 def _is_hidden_empty_session(s) -> bool:

tests/test_issue6869_gateway_launch_failure.py

@@ -183,3 +183,35 @@ def test_gateway_launch_failure_cleanup_does_not_resurrect_deleted_session(monke
     assert stale.active_stream_id == "old-stream"
     assert stale.pending_user_message == "pending prompt"
     assert saved == [], "cleanup must not save a deleted session"
+
+
+def test_gateway_launch_failure_cleanup_never_masks_the_launch_error(monkeypatch):
+    """A resolution failure during cleanup must not replace the launch error.
+
+    Cleanup runs inside the launch-failure handler, so an error it fails to
+    contain is reported instead of the real launch failure. Resolution can fail
+    with something other than KeyError when the session store is unreadable or
+    cannot be deserialized.
+    """
+    saved = []
+
+    def failing_resolver(sid, metadata_only=False):
+        raise OSError("session store unreadable")
+
+    monkeypatch.setattr(routes, "get_session", failing_resolver)
+    stale = _make_session(
+        "session-launch-resolution-error",
+        active_stream_id="old-stream",
+        pending_user_message="pending prompt",
+        save=lambda: saved.append("stale"),
+    )
+    _register_failed_stream(stale.session_id, "old-stream")
+
+    # Must not raise: the caller is already handling the launch failure.
+    routes._cleanup_chat_start_launch_failure(stale, "old-stream")
+
+    # The registry half still completed, and nothing was saved.
+    assert config.session_writeback_owner(stale.session_id) is None
+    assert "old-stream" not in config.STREAM_SESSION_OWNERS
+    assert "old-stream" not in config.STREAMS
+    assert saved == []