fix(models): repair provider-wrapped session overrides

CHANGELOG.md

@@ -69,6 +69,7 @@ Docs: https://docs.openclaw.ai
 - Models/config: explain missing `models.providers.<provider>.models[]` registration when a model exists only in `agents.defaults.models`, instead of returning a bare unknown-model error. Fixes #80089.
 - MCP/tools: prefix bundle MCP server/tool fragments that would start with digits, keeping generated tool names valid for Moonshot/Kimi and other strict providers. Fixes #79179.
 - Models/OpenRouter: treat `403 API key budget limit exceeded` as billing so model fallback advances instead of retrying the exhausted primary. Fixes #60191. Thanks @omgitsgela.
+- Models/OpenRouter: repair stale session overrides that lost the outer `openrouter/` provider wrapper, so sessions return to the configured OpenRouter model instead of failing as an unknown direct-provider model. Fixes #78161. Thanks @hjamal7-bit.
 - Kimi Code: use Kimi's stable `kimi-for-coding` API model id in bundled catalog, onboarding, and docs while normalizing legacy `kimi-code` and `k2p5` refs. Fixes #79965.
 - Volcengine/Kimi: strip provider-unsupported tool schema length and item constraint keywords for direct and coding-plan models so hosted Kimi runs do not reject message tools with `minLength`. Fixes #38817.
 - DeepSeek: backfill V4 `reasoning_content` replay fields for unowned OpenAI-compatible proxy providers, preventing follow-up request failures outside the bundled DeepSeek and OpenRouter routes. Fixes #79608.

src/agents/agent-command.live-model-switch.test.ts

@@ -241,6 +241,7 @@ vi.mock("../sessions/level-overrides.js", () => ({
 
 vi.mock("../sessions/model-overrides.js", () => ({
   applyModelOverrideToSessionEntry: () => ({ updated: false }),
+  repairProviderWrappedModelOverride: () => ({ updated: false }),
 }));
 
 vi.mock("../sessions/send-policy.js", () => ({

src/agents/agent-command.ts

@@ -24,7 +24,10 @@ import {
 } from "../routing/session-key.js";
 import { defaultRuntime, type RuntimeEnv } from "../runtime.js";
 import { applyVerboseOverride } from "../sessions/level-overrides.js";
-import { applyModelOverrideToSessionEntry } from "../sessions/model-overrides.js";
+import {
+  applyModelOverrideToSessionEntry,
+  repairProviderWrappedModelOverride,
+} from "../sessions/model-overrides.js";
 import { resolveSendPolicy } from "../sessions/send-policy.js";
 import { createLazyImportLoader } from "../shared/lazy-promise.js";
 import { normalizeOptionalString } from "../shared/string-coerce.js";
@@ -778,6 +781,19 @@ async function agentCommandInternal(
 
     if (sessionEntry && sessionStore && sessionKey && hasStoredOverride) {
       const entry = sessionEntry;
+      const repaired = repairProviderWrappedModelOverride({
+        entry,
+        defaultProvider,
+        defaultModel,
+      });
+      if (repaired.updated) {
+        await persistSessionEntry({
+          sessionStore,
+          sessionKey,
+          storePath,
+          entry,
+        });
+      }
       const overrideProvider = sessionEntry.providerOverride?.trim() || defaultProvider;
       const overrideModel = sessionEntry.modelOverride?.trim();
       if (overrideModel) {

src/sessions/model-overrides.test.ts

@@ -1,6 +1,9 @@
 import { describe, expect, it } from "vitest";
 import type { SessionEntry } from "../config/sessions.js";
-import { applyModelOverrideToSessionEntry } from "./model-overrides.js";
+import {
+  applyModelOverrideToSessionEntry,
+  repairProviderWrappedModelOverride,
+} from "./model-overrides.js";
 
 function applyOpenAiSelection(entry: SessionEntry) {
   return applyModelOverrideToSessionEntry({
@@ -173,3 +176,57 @@ describe("applyModelOverrideToSessionEntry", () => {
     expect(withFlagEntry.liveModelSwitchPending).toBe(true);
   });
 });
+
+describe("repairProviderWrappedModelOverride", () => {
+  it("restores a provider-wrapped override from aligned runtime model fields", () => {
+    const before = Date.now() - 5_000;
+    const entry: SessionEntry = {
+      sessionId: "sess-openrouter-repair-runtime",
+      updatedAt: before,
+      providerOverride: "anthropic",
+      modelOverride: "claude-haiku-4.5",
+      modelOverrideSource: "user",
+      modelProvider: "openrouter",
+      model: "anthropic/claude-haiku-4.5",
+      contextTokens: 200_000,
+    };
+
+    const result = repairProviderWrappedModelOverride({
+      entry,
+      defaultProvider: "openai",
+      defaultModel: "gpt-5.4",
+    });
+
+    expect(result.updated).toBe(true);
+    expect(entry.providerOverride).toBe("openrouter");
+    expect(entry.modelOverride).toBe("anthropic/claude-haiku-4.5");
+    expect(entry.modelOverrideSource).toBe("user");
+    expect(entry.modelProvider).toBeUndefined();
+    expect(entry.model).toBeUndefined();
+    expect(entry.contextTokens).toBeUndefined();
+    expect((entry.updatedAt ?? 0) > before).toBe(true);
+  });
+
+  it("clears a provider-wrapped override that matches the configured default", () => {
+    const before = Date.now() - 5_000;
+    const entry: SessionEntry = {
+      sessionId: "sess-openrouter-repair-default",
+      updatedAt: before,
+      providerOverride: "anthropic",
+      modelOverride: "claude-haiku-4.5",
+      modelOverrideSource: "user",
+    };
+
+    const result = repairProviderWrappedModelOverride({
+      entry,
+      defaultProvider: "openrouter",
+      defaultModel: "anthropic/claude-haiku-4.5",
+    });
+
+    expect(result.updated).toBe(true);
+    expect(entry.providerOverride).toBeUndefined();
+    expect(entry.modelOverride).toBeUndefined();
+    expect(entry.modelOverrideSource).toBeUndefined();
+    expect((entry.updatedAt ?? 0) > before).toBe(true);
+  });
+});

src/sessions/model-overrides.ts

@@ -125,3 +125,48 @@ export function applyModelOverrideToSessionEntry(params: {
 
   return { updated };
 }
+
+function wrappedOverrideModel(provider: string, model: string): string {
+  return `${provider}/${model}`;
+}
+
+export function repairProviderWrappedModelOverride(params: {
+  entry: SessionEntry;
+  defaultProvider: string;
+  defaultModel?: string;
+}): { updated: boolean } {
+  const overrideProvider = normalizeOptionalString(params.entry.providerOverride);
+  const overrideModel = normalizeOptionalString(params.entry.modelOverride);
+  if (!overrideProvider || !overrideModel) {
+    return { updated: false };
+  }
+
+  const wrappedModel = wrappedOverrideModel(overrideProvider, overrideModel);
+  const runtimeProvider = normalizeOptionalString(params.entry.modelProvider);
+  const runtimeModel = normalizeOptionalString(params.entry.model);
+  if (runtimeProvider && runtimeModel === wrappedModel && runtimeProvider !== overrideProvider) {
+    return applyModelOverrideToSessionEntry({
+      entry: params.entry,
+      selection: {
+        provider: runtimeProvider,
+        model: runtimeModel,
+        isDefault:
+          runtimeProvider === params.defaultProvider && runtimeModel === params.defaultModel,
+      },
+      selectionSource: params.entry.modelOverrideSource === "auto" ? "auto" : "user",
+    });
+  }
+
+  if (params.defaultProvider !== overrideProvider && params.defaultModel === wrappedModel) {
+    return applyModelOverrideToSessionEntry({
+      entry: params.entry,
+      selection: {
+        provider: params.defaultProvider,
+        model: params.defaultModel,
+        isDefault: true,
+      },
+    });
+  }
+
+  return { updated: false };
+}