Fix: Improve chunk load error handling

src/App.tsx

@@ -20,6 +20,8 @@ import { breadcrumb } from "@/lib/errorBreadcrumbs";
 import { handleError } from "@/lib/errorHandler";
 import { RetryStatusIndicator } from "@/components/ui/retry-status-indicator";
 import { APIStatusBanner } from "@/components/ui/api-status-banner";
+import { useAdminRoutePreload } from "@/hooks/useAdminRoutePreload";
+import { useVersionCheck } from "@/hooks/useVersionCheck";
 import { cn } from "@/lib/utils";
 
 // Core routes (eager-loaded for best UX)
@@ -136,6 +138,12 @@ function AppContent(): React.JSX.Element {
   // Check if API status banner is visible to add padding
   const { isAPIReachable, isBannerDismissed } = useAPIConnectivity();
   const showBanner = !isAPIReachable && !isBannerDismissed;
+  
+  // Preload admin routes for moderators/admins
+  useAdminRoutePreload();
+  
+  // Monitor for new deployments
+  useVersionCheck();
 
   return (
     <TooltipProvider>

src/components/error/RouteErrorBoundary.tsx

@@ -71,6 +71,32 @@ export class RouteErrorBoundary extends Component<RouteErrorBoundaryProps, Route
     window.location.reload();
   };
 
+  handleClearCacheAndReload = async () => {
+    try {
+      // Clear all caches
+      if ('caches' in window) {
+        const cacheNames = await caches.keys();
+        await Promise.all(cacheNames.map(name => caches.delete(name)));
+      }
+
+      // Unregister service workers
+      if ('serviceWorker' in navigator) {
+        const registrations = await navigator.serviceWorker.getRegistrations();
+        await Promise.all(registrations.map(reg => reg.unregister()));
+      }
+
+      // Clear session storage chunk reload flag
+      sessionStorage.removeItem('chunk-load-reload');
+
+      // Force reload bypassing cache
+      window.location.reload();
+    } catch (error) {
+      // Fallback to regular reload if cache clearing fails
+      console.error('Failed to clear cache:', error);
+      window.location.reload();
+    }
+  };
+
   handleGoHome = () => {
     window.location.href = '/';
   };
@@ -90,12 +116,23 @@ export class RouteErrorBoundary extends Component<RouteErrorBoundaryProps, Route
                 <AlertTriangle className="w-8 h-8 text-destructive" />
               </div>
               <CardTitle className="text-2xl">
-                {isChunkError ? 'New Version Available' : 'Something Went Wrong'}
+                {isChunkError ? 'App Update Required' : 'Something Went Wrong'}
               </CardTitle>
-              <CardDescription className="mt-2">
-                {isChunkError 
-                  ? "The app has been updated. Please reload the page to get the latest version."
-                  : "We encountered an unexpected error. This has been logged and we'll look into it."}
+              <CardDescription className="mt-2 space-y-2">
+                {isChunkError ? (
+                  <>
+                    <p>The app has been updated with new features and improvements.</p>
+                    <p className="text-sm font-medium">
+                      To continue, please clear your browser cache and reload:
+                    </p>
+                    <ul className="text-sm list-disc list-inside space-y-1 ml-2">
+                      <li>Click "Clear Cache & Reload" below, or</li>
+                      <li>Press <kbd className="px-1.5 py-0.5 text-xs font-semibold bg-muted rounded">Ctrl+Shift+R</kbd> (Windows/Linux) or <kbd className="px-1.5 py-0.5 text-xs font-semibold bg-muted rounded">⌘+Shift+R</kbd> (Mac)</li>
+                    </ul>
+                  </>
+                ) : (
+                  "We encountered an unexpected error. This has been logged and we'll look into it."
+                )}
               </CardDescription>
             </CardHeader>
             <CardContent className="space-y-4">
@@ -114,23 +151,35 @@ export class RouteErrorBoundary extends Component<RouteErrorBoundaryProps, Route
                 </div>
               )}
 
-              <div className="flex flex-col sm:flex-row gap-2">
-                <Button
-                  variant="default"
-                  onClick={this.handleReload}
-                  className="flex-1 gap-2"
-                >
-                  <RefreshCw className="w-4 h-4" />
-                  Reload Page
-                </Button>
-                <Button
-                  variant="outline"
-                  onClick={this.handleGoHome}
-                  className="flex-1 gap-2"
-                >
-                  <Home className="w-4 h-4" />
-                  Go Home
-                </Button>
+              <div className="flex flex-col gap-2">
+                {isChunkError && (
+                  <Button
+                    variant="default"
+                    onClick={this.handleClearCacheAndReload}
+                    className="w-full gap-2"
+                  >
+                    <RefreshCw className="w-4 h-4" />
+                    Clear Cache & Reload
+                  </Button>
+                )}
+                <div className="flex flex-col sm:flex-row gap-2">
+                  <Button
+                    variant={isChunkError ? "outline" : "default"}
+                    onClick={this.handleReload}
+                    className="flex-1 gap-2"
+                  >
+                    <RefreshCw className="w-4 h-4" />
+                    Reload Page
+                  </Button>
+                  <Button
+                    variant="outline"
+                    onClick={this.handleGoHome}
+                    className="flex-1 gap-2"
+                  >
+                    <Home className="w-4 h-4" />
+                    Go Home
+                  </Button>
+                </div>
               </div>
 
               <p className="text-xs text-center text-muted-foreground">

src/hooks/useAdminRoutePreload.ts

@@ -0,0 +1,39 @@
+import { useEffect } from 'react';
+import { useAuth } from './useAuth';
+import { useUserRole } from './useUserRole';
+
+/**
+ * Preloads admin route chunks for authenticated moderators/admins
+ * This reduces chunk load failures by warming up the browser cache
+ */
+export function useAdminRoutePreload() {
+  const { user } = useAuth();
+  const { isModerator, isAdmin } = useUserRole();
+
+  useEffect(() => {
+    // Only preload if user has admin access
+    if (!user || (!isModerator && !isAdmin)) {
+      return;
+    }
+
+    // Preload admin chunks after a short delay to avoid blocking initial page load
+    const preloadTimer = setTimeout(() => {
+      // Preload critical admin routes
+      const adminRoutes = [
+        () => import('../pages/AdminDashboard'),
+        () => import('../pages/AdminModeration'),
+        () => import('../pages/AdminReports'),
+      ];
+
+      // Start preloading (but don't await - let it happen in background)
+      adminRoutes.forEach(route => {
+        route().catch(err => {
+          // Silently fail - preloading is a performance optimization
+          console.debug('Admin route preload failed:', err);
+        });
+      });
+    }, 2000); // Wait 2 seconds after auth to avoid blocking initial render
+
+    return () => clearTimeout(preloadTimer);
+  }, [user, isModerator, isAdmin]);
+}

src/hooks/useVersionCheck.ts

@@ -0,0 +1,76 @@
+import { useEffect, useState } from 'react';
+import { toast } from 'sonner';
+
+// App version - automatically updated during build
+const APP_VERSION = import.meta.env.VITE_APP_VERSION || 'dev';
+const VERSION_CHECK_INTERVAL = 5 * 60 * 1000; // Check every 5 minutes
+
+/**
+ * Monitors for new app deployments and prompts user to refresh
+ */
+export function useVersionCheck() {
+  const [newVersionAvailable, setNewVersionAvailable] = useState(false);
+
+  useEffect(() => {
+    // Don't run in development
+    if (import.meta.env.DEV) {
+      return;
+    }
+
+    const checkVersion = async () => {
+      try {
+        // Fetch the current index.html with cache bypass
+        const response = await fetch('/', {
+          method: 'HEAD',
+          cache: 'no-cache',
+          headers: {
+            'Cache-Control': 'no-cache, no-store, must-revalidate',
+            'Pragma': 'no-cache',
+          },
+        });
+
+        // Check ETag or Last-Modified to detect changes
+        const etag = response.headers.get('ETag');
+        const lastModified = response.headers.get('Last-Modified');
+        
+        const currentFingerprint = `${etag}-${lastModified}`;
+        const storedFingerprint = sessionStorage.getItem('app-version-fingerprint');
+
+        if (storedFingerprint && storedFingerprint !== currentFingerprint) {
+          // New version detected
+          setNewVersionAvailable(true);
+          
+          toast.info('New version available', {
+            description: 'A new version of ThrillWiki is available. Please refresh to update.',
+            duration: 30000, // Show for 30 seconds
+            action: {
+              label: 'Refresh Now',
+              onClick: () => window.location.reload(),
+            },
+          });
+        }
+
+        // Store current fingerprint
+        if (!storedFingerprint) {
+          sessionStorage.setItem('app-version-fingerprint', currentFingerprint);
+        }
+      } catch (error) {
+        // Silently fail - version check is non-critical
+        console.debug('Version check failed:', error);
+      }
+    };
+
+    // Initial check after 1 minute (give time for user to settle in)
+    const initialTimer = setTimeout(checkVersion, 60000);
+
+    // Then check periodically
+    const interval = setInterval(checkVersion, VERSION_CHECK_INTERVAL);
+
+    return () => {
+      clearTimeout(initialTimer);
+      clearInterval(interval);
+    };
+  }, []);
+
+  return { newVersionAvailable };
+}