chore(deps): zod 3→4 major

package.json

@@ -33,5 +33,11 @@
   "engines": {
     "node": ">=20.0.0",
     "npm": ">=9.0.0"
+  },
+  "overrides": {
+    "zod": "^4.4.3",
+    "@anthropic-ai/claude-agent-sdk": {
+      "zod": "^4.4.3"
+    }
   }
 }

packages/autonav/package.json

@@ -64,7 +64,7 @@
     "ora": "^9.4.1",
     "react": "^18.3.1",
     "tar": "^7.5.19",
-    "zod": "^3.24.1"
+    "zod": "^4.4.3"
   },
   "devDependencies": {
     "@testing-library/react": "^14.0.0",

packages/autonav/src/harness/claude-code-harness.ts

@@ -343,7 +343,7 @@ export class ClaudeCodeHarness implements Harness {
   createToolServer(name: string, tools: ToolDefinition[]): { server: unknown } {
     const sdkTools = tools.map((td) =>
       // eslint-disable-next-line @typescript-eslint/no-explicit-any
-      tool(td.name, td.description, td.inputSchema, ((args: any) => td.handler(args)) as any)
+      tool(td.name, td.description, td.inputSchema as any, ((args: any) => td.handler(args)) as any)
     );
     const server = createSdkMcpServer({
       name,

packages/autonav/src/mend/index.ts

@@ -75,7 +75,7 @@ export async function checkNavigatorHealth(navPath: string): Promise<MendResult>
           check: "config.json schema",
           status: "fail",
           message: "config.json schema validation failed",
-          details: parseResult.error.errors.map(e => `${e.path.join('.')}: ${e.message}`).join("; "),
+          details: parseResult.error.issues.map(e => `${e.path.join('.')}: ${e.message}`).join("; "),
           autoFixable: false,
         });
       } else {

packages/autonav/src/plugins/config-schema.ts

@@ -23,7 +23,7 @@ export const PluginConfigFileSchema = z.record(
   z.string(), // Plugin name
   z.object({
     enabled: z.boolean(),
-    config: z.record(z.unknown()).optional(),
+    config: z.record(z.string(), z.unknown()).optional(),
   })
 );
 

packages/autonav/src/plugins/plugin-manager.ts

@@ -9,7 +9,7 @@ export const PluginsConfigSchema = z.record(
   z.string(), // Plugin name
   z.object({
     enabled: z.boolean(),
-    config: z.record(z.unknown()).optional(), // Plugin-specific config
+    config: z.record(z.string(), z.unknown()).optional(), // Plugin-specific config
   })
 );
 

packages/autonav/src/tools/self-config.ts

@@ -81,7 +81,7 @@ This allows you to autonomously manage your own behavior based on user requests.
       plugin: z.enum(CONFIGURABLE_PLUGINS).describe(
         "The plugin to configure (slack, signal, github, or email)"
       ),
-      updates: z.record(z.unknown()).describe(
+      updates: z.record(z.string(), z.unknown()).describe(
         `Configuration updates to apply. Common patterns:
 - signal: { checkInSchedule: "custom", nextCheckIn: "2025-01-15T15:00:00Z", notificationTypes: ["urgent"] }
 - slack: { channels: ["platform-team"], summaryFrequency: "weekly" }

packages/communication-layer/package.json

@@ -42,7 +42,7 @@
     "url": "https://github.com/terraboops/autonav/issues"
   },
   "dependencies": {
-    "zod": "^3.25.76"
+    "zod": "^4.4.3"
   },
   "devDependencies": {
     "@types/node": "^20.0.0",

packages/communication-layer/src/schemas/config-describe.ts

@@ -24,57 +24,62 @@ interface FieldInfo {
 // ── Schema analysis ─────────────────────────────────────────────────────────
 
 function analyzeZodField(schema: z.ZodTypeAny): FieldInfo {
-  const def = schema._def as Record<string, unknown>;
-  const typeName = def.typeName as string;
+  // Zod 4 exposes the internal definition under `_zod.def` and uses lowercase
+  // `type` discriminators (e.g. "string", "optional") instead of `typeName`.
+  const def = (schema as unknown as { _zod: { def: Record<string, unknown> } })._zod.def;
+  const type = def.type as string;
+  // Descriptions now live in the global registry, surfaced via `.description`.
+  const ownDescription = (schema.description as string | undefined) || '';
 
   // Unwrap wrapper types (order matters: optional/default/nullable are outermost)
-  if (typeName === 'ZodOptional') {
+  if (type === 'optional') {
     const inner = analyzeZodField(def.innerType as z.ZodTypeAny);
     inner.optional = true;
-    if (!inner.description && def.description) inner.description = def.description as string;
+    if (!inner.description && ownDescription) inner.description = ownDescription;
     return inner;
   }
 
-  if (typeName === 'ZodDefault') {
+  if (type === 'default') {
     const inner = analyzeZodField(def.innerType as z.ZodTypeAny);
     inner.optional = true; // has default → not required in JSON
-    inner.defaultValue = (def.defaultValue as () => unknown)();
-    if (!inner.description && def.description) inner.description = def.description as string;
+    // In Zod 4 `defaultValue` is the value itself (no longer a factory function).
+    inner.defaultValue = def.defaultValue;
+    if (!inner.description && ownDescription) inner.description = ownDescription;
     return inner;
   }
 
-  if (typeName === 'ZodNullable') {
+  if (type === 'nullable') {
     const inner = analyzeZodField(def.innerType as z.ZodTypeAny);
     inner.type += ' | null';
-    if (!inner.description && def.description) inner.description = def.description as string;
+    if (!inner.description && ownDescription) inner.description = ownDescription;
     return inner;
   }
 
   // Base types
-  const description = (def.description as string) || '';
+  const description = ownDescription;
 
-  if (typeName === 'ZodString') {
+  if (type === 'string') {
     return { type: 'string', description, optional: false };
   }
-  if (typeName === 'ZodNumber') {
+  if (type === 'number') {
     return { type: 'number', description, optional: false };
   }
-  if (typeName === 'ZodBoolean') {
+  if (type === 'boolean') {
     return { type: 'boolean', description, optional: false };
   }
-  if (typeName === 'ZodEnum') {
+  if (type === 'enum') {
     return {
       type: 'enum',
       description,
       optional: false,
-      enumValues: def.values as string[],
+      enumValues: Object.values(def.entries as Record<string, string>),
     };
   }
-  if (typeName === 'ZodRecord') {
+  if (type === 'record') {
     return { type: 'object (key-value pairs)', description, optional: false };
   }
-  if (typeName === 'ZodArray') {
-    const itemType = def.type as z.ZodTypeAny;
+  if (type === 'array') {
+    const itemType = def.element as z.ZodTypeAny;
     const itemInfo = analyzeZodField(itemType);
     if (itemInfo.children) {
       return {
@@ -86,7 +91,7 @@ function analyzeZodField(schema: z.ZodTypeAny): FieldInfo {
     }
     return { type: `${itemInfo.type}[]`, description, optional: false };
   }
-  if (typeName === 'ZodObject') {
+  if (type === 'object') {
     const shape = (schema as z.ZodObject<z.ZodRawShape>).shape;
     const children: Record<string, FieldInfo> = {};
     for (const [key, childField] of Object.entries(shape)) {

packages/communication-layer/src/schemas/config.ts

@@ -42,7 +42,7 @@ const SafeCommandSchema = z.string()
   .min(1, 'Command cannot be empty')
   .refine(
     (cmd) => !DENIED_SANDBOX_COMMANDS.has(cmd.toLowerCase()),
-    (cmd) => ({ message: `Command "${cmd}" is denied — it could bypass sandbox enforcement` })
+    'Command is denied — it could bypass sandbox enforcement'
   )
   .refine(
     (cmd) => !cmd.includes('/'),
@@ -111,7 +111,7 @@ export const NavigatorConfigSchema = z.object({
    * Additional configuration options
    * For future extensions without breaking changes
    */
-  metadata: z.record(z.unknown()).optional().describe('Additional metadata'),
+  metadata: z.record(z.string(), z.unknown()).optional().describe('Additional metadata'),
 
   /**
    * Knowledge pack metadata

packages/communication-layer/src/schemas/navigator-response.ts

@@ -44,7 +44,7 @@ export const NavigatorResponseSchema = z.object({
    * Additional metadata for future extensions
    * Examples: search strategy used, tokens consumed, execution time
    */
-  metadata: z.record(z.unknown()).optional(),
+  metadata: z.record(z.string(), z.unknown()).optional(),
 
   /**
    * Timestamp when the response was generated

packages/communication-layer/src/schemas/plugin-config.ts

@@ -114,7 +114,7 @@ export function validatePluginConfig(config: unknown): {
 
   return {
     valid: false,
-    errors: result.error.errors.map((e: { path: Array<string | number>; message: string }) =>
+    errors: result.error.issues.map((e: { path: PropertyKey[]; message: string }) =>
       `${e.path.join('.')}: ${e.message}`
     ),
   };

packages/knowledge-pack-server/package.json

@@ -29,7 +29,7 @@
   "license": "TBD",
   "dependencies": {
     "express": "^5.2.1",
-    "zod": "^3.22.4"
+    "zod": "^4.4.3"
   },
   "devDependencies": {
     "@types/express": "^5.0.6",