fix(agents/failover): classify bare pi-ai stream wrapper as timeout regardless of provider (#71620)

CHANGELOG.md

@@ -399,6 +399,7 @@ Docs: https://docs.openclaw.ai
 - Agents/sessions: stop session write-lock timeouts from entering model failover, so local lock contention surfaces directly instead of cascading across providers. (#68700) Thanks @MonkeyLeeT.
 - Auto-reply: run inbound reply delivery through `message_sending` hooks so plugins can transform or cancel generated replies before they are sent. (#70118) Thanks @jzakirov.
 - CI/release-checks: pass workflow inputs and matrix values through step environment variables instead of embedding them directly into `run:` shell commands, reducing template-injection surface in the cross-OS release-check workflow. (#66884) Thanks @alexlomt.
+- Agents/failover: classify the bare `An unknown error occurred` stream-wrapper message that pi-ai providers throw when streams end with `stopReason: "aborted" | "error"` as a transient timeout regardless of provider, so configured fallback chains rotate for non-Anthropic providers (Google, OpenRouter, Bedrock, etc.) instead of surfacing the literal string to users. Fixes #71620. Thanks @mattcproctor.
 
 ## 2026.4.23
 

src/agents/failover-error.test.ts

@@ -441,13 +441,33 @@ describe("failover-error", () => {
     ).toBeNull();
   });
 
-  it("classifies provider-scoped generic upstream errors for failover", () => {
+  it("classifies bare pi-ai stream wrapper as timeout regardless of provider (#71620)", () => {
+    expect(
+      resolveFailoverReasonFromError({
+        message: "An unknown error occurred",
+      }),
+    ).toBe("timeout");
     expect(
       resolveFailoverReasonFromError({
         provider: "anthropic",
         message: "An unknown error occurred",
       }),
     ).toBe("timeout");
+    expect(
+      resolveFailoverReasonFromError({
+        provider: "google",
+        message: "An unknown error occurred",
+      }),
+    ).toBe("timeout");
+    expect(
+      resolveFailoverReasonFromError({
+        provider: "openrouter",
+        message: "An unknown error occurred",
+      }),
+    ).toBe("timeout");
+  });
+
+  it("classifies openrouter-scoped upstream errors for failover", () => {
     expect(
       resolveFailoverReasonFromError({
         provider: "openrouter",
@@ -456,18 +476,7 @@ describe("failover-error", () => {
     ).toBe("timeout");
   });
 
-  it("does not classify provider-scoped upstream errors without the matching provider", () => {
-    expect(
-      resolveFailoverReasonFromError({
-        message: "An unknown error occurred",
-      }),
-    ).toBeNull();
-    expect(
-      resolveFailoverReasonFromError({
-        provider: "openrouter",
-        message: "An unknown error occurred",
-      }),
-    ).toBeNull();
+  it("does not classify openrouter-scoped upstream errors without the matching provider", () => {
     expect(
       resolveFailoverReasonFromError({
         message: "Provider returned error",

src/agents/pi-embedded-helpers.isbillingerrormessage.test.ts

@@ -739,10 +739,39 @@ describe("classifyFailoverReason", () => {
     expect(isFailoverErrorMessage(message)).toBe(true);
   });
 
-  it("classifies provider-scoped generic upstream messages", () => {
+  it("classifies bare pi-ai stream wrapper as timeout regardless of provider (#71620)", () => {
+    // pi-ai providers throw `Error("An unknown error occurred")` provider-agnostically
+    // when streams end with stopReason "aborted" | "error" with no specific info.
+    for (const sample of [
+      "An unknown error occurred",
+      "an unknown error occurred",
+      "AN UNKNOWN ERROR OCCURRED",
+      "An unknown error occurred.",
+      "  An unknown error occurred  ",
+    ]) {
+      expect(classifyFailoverReason(sample)).toBe("timeout");
+      expect(isFailoverErrorMessage(sample)).toBe(true);
+    }
     expect(classifyFailoverReason("An unknown error occurred", { provider: "anthropic" })).toBe(
       "timeout",
     );
+    expect(classifyFailoverReason("An unknown error occurred", { provider: "google" })).toBe(
+      "timeout",
+    );
+    expect(classifyFailoverReason("An unknown error occurred", { provider: "openrouter" })).toBe(
+      "timeout",
+    );
+  });
+
+  it("does not match wrapped or unrelated unknown-error phrases as bare wrapper", () => {
+    // Wrapped messages must not slip into failover-as-timeout via the bare match.
+    expect(classifyFailoverReason("LLM request failed with an unknown error.")).toBeNull();
+    expect(
+      classifyFailoverReason("user reported that an unknown error occurred during sync"),
+    ).toBeNull();
+  });
+
+  it("classifies openrouter-scoped upstream messages", () => {
     expect(classifyFailoverReason("Provider returned error", { provider: "openrouter" })).toBe(
       "timeout",
     );
@@ -751,11 +780,7 @@ describe("classifyFailoverReason", () => {
     );
   });
 
-  it("does not classify provider-scoped generic upstream messages without provider context", () => {
-    expect(classifyFailoverReason("An unknown error occurred")).toBeNull();
-    expect(
-      classifyFailoverReason("An unknown error occurred", { provider: "openrouter" }),
-    ).toBeNull();
+  it("does not classify openrouter-scoped upstream messages without provider context", () => {
     expect(classifyFailoverReason("Provider returned error")).toBeNull();
     expect(classifyFailoverReason("Provider returned error", { provider: "anthropic" })).toBeNull();
     expect(classifyFailoverReason("Key limit exceeded")).toBeNull();

src/agents/pi-embedded-helpers/errors.ts

@@ -753,11 +753,13 @@ function isProvider(provider: string | undefined, match: string): boolean {
   return Boolean(normalized && normalized.includes(match));
 }
 
-function isAnthropicGenericUnknownError(raw: string, provider?: string): boolean {
-  return (
-    isProvider(provider, "anthropic") &&
-    (normalizeOptionalLowercaseString(raw)?.includes("an unknown error occurred") ?? false)
-  );
+// pi-ai providers throw `Error("An unknown error occurred")` provider-agnostically
+// (anthropic, google, vertex, openai-completions, mistral, bedrock, etc.) when a
+// stream ends with stopReason === "aborted" | "error" without specific info. Treat
+// it as a transient transport failure so the configured fallback chain rotates
+// instead of returning the bare string to the user (#71620).
+function isGenericUnknownStreamError(raw: string): boolean {
+  return /^\s*an unknown error occurred\.?\s*$/i.test(raw);
 }
 
 function isOpenRouterProviderReturnedError(raw: string, provider?: string): boolean {
@@ -833,7 +835,7 @@ function classifyFailoverClassificationFromMessage(
   if (isAuthErrorMessage(raw)) {
     return toReasonClassification("auth");
   }
-  if (isAnthropicGenericUnknownError(raw, provider)) {
+  if (isGenericUnknownStreamError(raw)) {
     return toReasonClassification("timeout");
   }
   if (isOpenRouterProviderReturnedError(raw, provider)) {