fix(ai): match retryable status codes only as standalone numbers

Status codes inside request ids or other numbers no longer make an error retryable.

closes #11057

packages/ai/CHANGELOG.md

@@ -23,6 +23,7 @@
 - Fixed whitespace-only tool output (for example a bare `\r\n` from bash) being sent as-is to OpenAI Completions, OpenAI Responses, and Google providers; it now uses the same placeholder as empty output, since some providers reject whitespace-only tool content with a 400 ([#8720](https://github.com/earendil-works/pi/issues/8720))
 - Fixed automatic retry not triggering for gateway upstream failures such as `upstream_error: Upstream request failed`, `upstream_stream_read_error`, and `Upstream HTTP/2 stream failed` ([#10920](https://github.com/earendil-works/pi/issues/10920))
 - Fixed automatic retry not triggering for `stream disconnected before completion` errors relayed by proxies that wrap the Codex CLI ([#11057](https://github.com/earendil-works/pi/issues/11057))
+- Fixed automatic retry treating digits inside request ids or other numbers (for example `req_011CU503xyz` or `5242880 bytes`) as retryable HTTP status codes ([#11057](https://github.com/earendil-works/pi/issues/11057))
 - Fixed OpenAI Responses deferred tool loads rewriting the top-level tool list, and losing the prompt cache, on every load after a tool removal. Models with `additional_tools` now declare all tools in `additional_tools` items, starting with one at the head of the input, so removals (announced as text) and redefinitions no longer rewrite the prefix. Tool search and Kimi tool messages rewrite the top-level tools once per removal or redeclaration and keep later loads anchored ([#10940](https://github.com/earendil-works/pi/issues/10940))
 
 ## [1.3.0] - 2026-10-15

packages/ai/src/utils/retry.ts

@@ -39,13 +39,8 @@ const RETRYABLE_PROVIDER_ERROR_PATTERN = buildProviderErrorPattern([
 	"model is at capacity",
 	"rate.?limit",
 	"too many requests",
-	"429",
-	"500",
-	"502",
-	"503",
-	"504",
-	"520",
-	"524",
+	// Status codes must not be part of a longer word or number, e.g. a request id or byte count (#11057).
+	"(?<![a-z0-9])(?:429|500|502|503|504|520|524)(?![a-z0-9])",
 	// Also matches "The service is temporarily unavailable" (#10965).
 	"service.?(?:is.?)?(?:temporarily.?)?unavailable",
 	"server.?error",

packages/ai/test/retry.test.ts

@@ -156,6 +156,14 @@ describe("provider retry classification", () => {
 		).toBe(true);
 		expect(isRetryableAssistantError(fauxAssistantMessage("not an error"))).toBe(false);
 	});
+
+	it.each([
+		// Regression for #11057: status codes inside ids or other numbers are not status codes.
+		'401 {"type":"error","error":{"type":"authentication_error","message":"invalid x-api-key"},"request_id":"req_011CU503xyz"}',
+		"400 image exceeds 5 MB maximum: 5316784 bytes > 5242880 bytes",
+	])("does not match status codes inside ids or longer numbers: %s", (errorMessage) => {
+		expect(isRetryableAssistantError(fauxAssistantMessage("", { stopReason: "error", errorMessage }))).toBe(false);
+	});
 });
 
 describe("retryDelayMs", () => {