reopening the MFA setup screen while MFA is enabled no longer wipes the secret and backup codes

src/lib/server/auth.ts

@@ -937,10 +937,16 @@ function parseMfaData(mfaSecret: string | null | undefined): MfaData | null {
 export async function generateMfaSetup(userId: number): Promise<{
 	secret: string;
 	qrDataUrl: string;
-} | null> {
+} | { alreadyEnabled: true } | null> {
 	const user = await getUser(userId);
 	if (!user) return null;
 
+	// Never regenerate over a LIVE enrolment. Overwriting the stored secret + clearing
+	// backupCodes while mfaEnabled stays true locks the account out for good (#1399): the
+	// authenticator holds the old secret, no backup code can match, and login keeps demanding
+	// a code. To re-enrol, the user must disable MFA first (DELETE), then set it up fresh.
+	if (user.mfaEnabled) return { alreadyEnabled: true };
+
 	// Build issuer name with hostname (same as license matching)
 	const hostname = process.env.DOCKHAND_HOSTNAME || os.hostname();
 	const issuer = `Dockhand (${hostname})`;

src/routes/api/users/[id]/mfa/+server.ts

@@ -55,11 +55,24 @@ export const POST: RequestHandler = async (event) => {
 			});
 		}
 
+		// Only an explicit setup request regenerates. Treating "anything not verify" as
+		// "regenerate" let a stray/empty POST (a restored tab, a refresh) destroy a live MFA
+		// enrolment (#1399). An empty body still means setup for backward-compat with the current
+		// client, but a body with a DIFFERENT action is rejected rather than silently regenerating.
+		if (body.action && body.action !== 'setup') {
+			return json({ error: `Unknown MFA action "${body.action}"` }, { status: 400 });
+		}
+
 		// Generate new MFA setup
 		const setup = await generateMfaSetup(userId);
 		if (!setup) {
 			return json({ error: 'User not found' }, { status: 404 });
 		}
+		if ('alreadyEnabled' in setup) {
+			// Refuse to overwrite a live enrolment - would lock the user out (#1399). They must
+			// disable MFA first, then set it up again.
+			return json({ error: 'MFA is already enabled. Disable it before setting it up again.' }, { status: 409 });
+		}
 
 		return json({
 			secret: setup.secret,