src/app/routes/__root.tsx

@@ -127,6 +127,11 @@ export const Route = createRootRouteWithContext<{
 
       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/features/players/server.ts

@@ -15,7 +15,7 @@ export const fetchMe = createServerFn()
       const request = getRequest();
 
       try {
-        const context = await getSessionContext(request);
+        const context = await getSessionContext(request, { isServerFunction: true });
 
         await pbAdmin.authPromise;
         const result = await pbAdmin.getPlayerByAuthId(context.userAuthId);
@@ -55,6 +55,24 @@ export const fetchMe = createServerFn()
           }
         }
 
+        if (error?.message === "SESSION_REFRESH_REQUIRED") {
+          logger.info("FetchMe: Session refresh required (server function)");
+          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"
+              }
+            }
+          );
+        }
+
         if (error?.message === "Unauthenticated") {
           logger.info("FetchMe: No authenticated user (expected when not logged in)");
           return { user: undefined, roles: [], metadata: {}, phone: undefined };

src/lib/tanstack-query/utils/ensure.ts

@@ -11,13 +11,20 @@ export async function ensureServerQueryData<TData>(
   return queryClient.ensureQueryData({
     queryKey: query.queryKey,
     queryFn: async () => {
-      const result = await query.queryFn();
-      
-      if (!result.success) {
-        throw new Error(result.error.userMessage);
+      try {
+        const result = await query.queryFn();
+
+        if (!result.success) {
+          throw new Error(result.error.userMessage);
+        }
+
+        return result.data;
+      } catch (error: any) {
+        if (error?.options?.to && error?.options?.statusCode) {
+          throw error;
+        }
+        throw error;
       }
-      
-      return result.data;
     }
   });
 }

src/lib/tanstack-query/utils/global-error-handler.ts

@@ -10,6 +10,11 @@ export async function handleQueryError(error: any): Promise<void> {
     throw error;
   }
 
+  if (error.options?.to && error.options?.statusCode) {
+    logger.info('handleQueryError: Re-throwing TanStack Router redirect', error.options);
+    throw error;
+  }
+
   if (error instanceof Response) {
     const status = error.status;
 

src/lib/tanstack-query/utils/to-server-result.ts

@@ -26,6 +26,14 @@ export const toServerResult = async <T>(
     const data = await serverFn();
     return { success: true, data };
   } catch (error) {
+    if (error && typeof error === 'object' && 'options' in error) {
+      const redirectError = error as any;
+      if (redirectError.options?.to && redirectError.options?.statusCode) {
+        logger.info('toServerResult: Re-throwing TanStack Router redirect', redirectError.options);
+        throw error;
+      }
+    }
+
     const duration = Date.now() - startTime;
     logger.error('Server Fn Error', error);