fix(fs): Windows-safe atomic replace everywhere — model switch now sticks

Root cause of 'model+effort switch works on Mac, not on Windows': the
switch APPLIES in-session (the dispatch/apply chain is platform-identical,
verified adversarially) but its persistence never sticks on Windows.
Every tmp+rename atomic write except auth/storage.rs committed with a
bare fs::rename, and Windows MoveFileExW(REPLACE_EXISTING) fails with a
sharing violation whenever AV/search-indexer/cloud-sync transiently holds
the destination open. Consequences: [models].default never persisted
(next launch = original model), the session summary's current model never
persisted (resume = original model), and the models cache went silently
stale (all its write errors were swallowed).

- New kigi_shell_base::util::fs::replace_file — THE commit step for
  tmp+rename: plain rename on Unix; on Windows delete-first + two short
  backoffs (the pattern auth/storage.rs shipped first), tmp cleaned on
  failure, error always returned. Windows branch type-checked against
  x86_64-pc-windows-msvc.
- Adopted at every replace site: config.toml (save_config /
  atomic_write_string / mcp saves), models cache (plus unique tmp
  suffixes and tracing::warn on failure — writes were fully silent),
  session storage (summary/current-model, jsonl, plan/signals/
  announcement/goal/graph state), auth.json, active-sessions registry,
  prompt history, claude/kimi import, campaigns state, goal artifacts.
  Directory-move renames (worktree pool, corrupt-file backups) keep
  plain rename — their destinations don't pre-exist.

Verified: kigi-shell + kigi-shell-base 5318 tests green, clippy clean,
msvc-target check of the new cfg(windows) code clean.

crates/codegen/kigi-shell/src/session/acp_session.rs

@@ -1147,7 +1147,7 @@ fn persist_chat_history_jsonl_sync(session_info: &SessionInfo, conversation: &[C
             buf.push(b'\n');
         }
         std::fs::File::create(&tmp_path)?.write_all(&buf)?;
-        std::fs::rename(&tmp_path, &final_path)?;
+        crate::util::fs::replace_file(&tmp_path, &final_path)?;
         Ok(())
     })();
     if let Err(e) = result {

crates/codegen/kigi-shell/src/session/goal_classifier.rs

@@ -594,10 +594,10 @@ async fn write_patch_file_atomic(path: &Path, body: &str) -> std::io::Result<()>
         .unwrap_or("goal-classifier.patch");
     let tmp = dir.join(format!(".{file_name}.{}.tmp", uuid::Uuid::now_v7()));
     tokio::fs::write(&tmp, body).await?;
-    if let Err(err) = tokio::fs::rename(&tmp, path).await {
-        let _ = tokio::fs::remove_file(&tmp).await;
-        return Err(err);
-    }
+    let dest = path.to_path_buf();
+    tokio::task::spawn_blocking(move || crate::util::fs::replace_file(&tmp, &dest))
+        .await
+        .map_err(std::io::Error::other)??;
     Ok(())
 }
 

crates/codegen/kigi-shell/src/session/goal_tracker.rs

@@ -895,7 +895,8 @@ impl GoalTracker {
         };
         let dest = goal_dir.join(name);
         let _ = std::fs::create_dir_all(&goal_dir);
-        if std::fs::rename(&src, &dest).is_ok() || copy_no_follow(&src, &dest).is_ok() {
+        if crate::util::fs::replace_file(&src, &dest).is_ok() || copy_no_follow(&src, &dest).is_ok()
+        {
             append_skeptic_reports(&scratch_root, &dest);
             o.last_classifier_details_path = Some(dest.to_string_lossy().into_owned());
         }

crates/codegen/kigi-shell/src/session/graph_project.rs

@@ -120,7 +120,7 @@ pub fn project(dir: &Path, state: &GraphOrchestration) -> std::io::Result<()> {
         f.write_all(&buf)?;
         f.sync_all()?;
     }
-    std::fs::rename(&tmp, &target)
+    crate::util::fs::replace_file(&tmp, &target)
 }
 
 /// Load the projected graph, `Ok(None)` when absent. Malformed content

crates/codegen/kigi-shell/src/session/prompt_history.rs

@@ -98,7 +98,7 @@ pub fn truncate_if_needed(cwd: &str) -> io::Result<()> {
         }
     }
 
-    std::fs::rename(temp_path, path)?;
+    crate::util::fs::replace_file(&temp_path, &path)?;
     Ok(())
 }
 

crates/codegen/kigi-shell/src/session/storage/jsonl/mod.rs

@@ -13,6 +13,16 @@ use std::fs::OpenOptions;
 use std::io::{self, Read};
 use std::path::{Path, PathBuf};
 use tokio::io::AsyncWriteExt;
+
+/// Commit `tmp` over `target` with the shared Windows-safe replace
+/// (`util::fs::replace_file`): a bare async rename silently lost session
+/// state — including the switched model — on Windows whenever AV/indexer
+/// held the destination open.
+async fn replace_file_async(tmp: PathBuf, target: PathBuf) -> io::Result<()> {
+    tokio::task::spawn_blocking(move || crate::util::fs::replace_file(&tmp, &target))
+        .await
+        .unwrap_or_else(|e| Err(io::Error::other(e)))
+}
 /// How the adapter resolves the session directory on disk.
 ///
 /// - `FromRoot` (default): computes `{root}/sessions/{urlencoded(cwd)}/{session_id}/`
@@ -289,7 +299,7 @@ impl JsonlStorageAdapter {
         }
         let tmp = path.with_extension("jsonl.tmp");
         tokio::fs::write(&tmp, &content).await?;
-        tokio::fs::rename(&tmp, &path).await
+        replace_file_async(tmp, path).await
     }
     fn read_jsonl<T: serde::de::DeserializeOwned>(&self, path: PathBuf) -> io::Result<Vec<T>> {
         if !path.exists() {
@@ -378,7 +388,7 @@ impl JsonlStorageAdapter {
             .map_err(|e| io::Error::new(io::ErrorKind::InvalidData, e))?;
         let tmp = summary_path.with_extension("json.tmp");
         std::fs::write(&tmp, &bytes)?;
-        std::fs::rename(&tmp, &summary_path)
+        crate::util::fs::replace_file(&tmp, &summary_path)
     }
     fn read_summary_sync(&self, info: &Info) -> io::Result<Summary> {
         let path = self.summary_file(info);
@@ -1057,7 +1067,7 @@ impl StorageAdapter for JsonlStorageAdapter {
         let target = self.plan_mode_state_file(info);
         let tmp = target.with_extension("json.tmp");
         tokio::fs::write(&tmp, json).await?;
-        tokio::fs::rename(&tmp, &target).await
+        replace_file_async(tmp, target).await
     }
     async fn write_signals(
         &self,
@@ -1069,7 +1079,7 @@ impl StorageAdapter for JsonlStorageAdapter {
         let target = self.signals_file(info);
         let tmp = target.with_extension("json.tmp");
         tokio::fs::write(&tmp, signals_json).await?;
-        tokio::fs::rename(&tmp, &target).await
+        replace_file_async(tmp, target).await
     }
     async fn write_announcement_state(
         &self,
@@ -1081,7 +1091,7 @@ impl StorageAdapter for JsonlStorageAdapter {
         let target = self.announcement_state_file(info);
         let tmp = target.with_extension("json.tmp");
         tokio::fs::write(&tmp, json).await?;
-        tokio::fs::rename(&tmp, &target).await
+        replace_file_async(tmp, target).await
     }
     async fn write_goal_mode_state(
         &self,
@@ -1096,7 +1106,7 @@ impl StorageAdapter for JsonlStorageAdapter {
         }
         let tmp = target.with_extension("json.tmp");
         tokio::fs::write(&tmp, json).await?;
-        tokio::fs::rename(&tmp, &target).await
+        replace_file_async(tmp, target).await
     }
     async fn write_graph_mode_state(
         &self,
@@ -1119,7 +1129,7 @@ impl StorageAdapter for JsonlStorageAdapter {
         }
         let tmp = target.with_extension("json.tmp");
         tokio::fs::write(&tmp, json).await?;
-        tokio::fs::rename(&tmp, &target).await
+        replace_file_async(tmp, target).await
     }
     async fn load_session(&self, info: &Info) -> io::Result<PersistedData> {
         let summary = self.read_summary_sync(info)?;

crates/codegen/kigi-shell/src/session/storage/summary_write.rs

@@ -230,7 +230,10 @@ fn write_summary_atomic(summary_path: &Path, summary: &Summary) -> io::Result<()
         .map_err(|e| io::Error::new(io::ErrorKind::InvalidData, e))?;
     let tmp = summary_path.with_extension("json.tmp");
     std::fs::write(&tmp, &bytes)?;
-    std::fs::rename(&tmp, summary_path)
+    // Windows-safe replace: this is the write that persists a session's
+    // CURRENT MODEL — a bare rename made a switched model silently revert
+    // on resume whenever AV/indexer held summary.json open on Windows.
+    crate::util::fs::replace_file(&tmp, summary_path)
 }
 
 #[cfg(test)]