try this

src/app/routes/__root.tsx

@@ -123,16 +123,8 @@ export const Route = createRootRouteWithContext<{
         playerQueries.auth()
       );
 
-      console.log('__root beforeLoad auth data:', auth);
-
       return { auth };
     } catch (error: any) {
-      if (error?.options?.to && error?.options?.statusCode) {
-        console.log('__root beforeLoad: Re-throwing redirect', error.options);
-        throw error;
-      }
-
-      console.error('__root beforeLoad error:', error);
       return {};
     }
   },

src/utils/supertokens.ts

@@ -4,7 +4,6 @@ import {
   createServerOnlyFn,
 } from "@tanstack/react-start";
 import { getRequest, setResponseHeader } from "@tanstack/react-start/server";
-import { redirect as redirect } from "@tanstack/react-router";
 import UserRoles from "supertokens-node/recipe/userroles";
 import UserMetadata from "supertokens-node/recipe/usermetadata";
 import { getSessionForStart } from "@/lib/supertokens/recipes/start-session";
@@ -48,26 +47,12 @@ const verifySuperTokensSession = async (
   };
 };
 
-export const getSessionContext = createServerOnlyFn(async (request: Request, options?: { isServerFunction?: boolean }) => {
+export const getSessionContext = createServerOnlyFn(async (request: Request) => {
   const session = await verifySuperTokensSession(request);
 
   if (session.context.session?.tryRefresh) {
-    if (options?.isServerFunction) {
+    logger.info("Session needs refresh - treating as unauthenticated");
-      throw new Error("SESSION_REFRESH_REQUIRED");
+    throw new Error("Unauthenticated");
-    }
-
-    const url = new URL(request.url);
-
-    if (url.pathname === '/refresh-session') {
-      logger.warn("Already on refresh-session page but session needs refresh - treating as unauthenticated");
-      throw new Error("Unauthenticated");
-    }
-
-    const from = encodeURIComponent(url.pathname + url.search);
-    throw redirect({
-      to: "/refresh-session",
-      search: { redirect: from }
-    });
   }
 
   if (!session.context.userAuthId) {
@@ -109,25 +94,9 @@ export const superTokensFunctionMiddleware = createMiddleware({
   const request = getRequest();
 
   try {
-    const context = await getSessionContext(request, { isServerFunction: true });
+    const context = await getSessionContext(request);
     return next({ context });
   } catch (error: any) {
-    if (error.message === "SESSION_REFRESH_REQUIRED") {
-      throw new Response(
-        JSON.stringify({
-          error: "SESSION_REFRESH_REQUIRED",
-          message: "Session needs to be refreshed",
-          shouldRetry: true
-        }),
-        {
-          status: 440,
-          headers: {
-            "Content-Type": "application/json",
-            "X-Session-Expired": "true"
-          }
-        }
-      );
-    }
     throw error;
   }
 });
@@ -138,7 +107,7 @@ export const superTokensAdminFunctionMiddleware = createMiddleware({
   const request = getRequest();
 
   try {
-    const context = await getSessionContext(request, { isServerFunction: true });
+    const context = await getSessionContext(request);
 
     if (context.roles?.includes("Admin")) {
       return next({ context });
@@ -147,22 +116,6 @@ export const superTokensAdminFunctionMiddleware = createMiddleware({
     logger.error("Unauthorized user in admin function.", context);
     throw new Error("Unauthorized");
   } catch (error: any) {
-    if (error.message === "SESSION_REFRESH_REQUIRED") {
-      throw new Response(
-        JSON.stringify({
-          error: "SESSION_REFRESH_REQUIRED",
-          message: "Session needs to be refreshed",
-          shouldRetry: true
-        }),
-        {
-          status: 440,
-          headers: {
-            "Content-Type": "application/json",
-            "X-Session-Expired": "true"
-          }
-        }
-      );
-    }
     throw error;
   }
 });