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A cached project router outlives the caller's bearer token. syncUpstreams only created a McpdUpstream (which binds the token at construction) for server names not already registered, so after a token rotation every pre-rotation upstream kept posting the old bearer: six attached, healthy servers 401'd on tools/list forever — no error anywhere the client could see — while the two servers attached after the rotation worked. - discovery.ts: rebuild every upstream on every sync, so it always carries the current caller token and the current server id (also fixes a stale serverId after delete+recreate under the same name). - router.ts: record per-server discovery failures with their messages and expose them (getToolDiscoveryFailures). - gate.ts: a partial catalog is now loud — initialize instructions and the begin_session response name every attached server that contributed no tools and the error that silenced it. - tests: regression tests for token rebinding and serverId refresh. Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>