fix: normalize malformed assistant replay content (#82748)

CHANGELOG.md

@@ -33,6 +33,7 @@ Docs: https://docs.openclaw.ai
 - System prompts: clarify MEMORY guidance over generic TTS hints in the embedded speech-core/system-prompt scaffolding so agents prefer memory-store usage over speech defaults. Fixes #81930. Thanks @giodl73-repo.
 - Agents/auth: include the checked credential source in missing API key errors, so users can see which env var, profile, or config path to fix. Fixes #82785. Thanks @loeclos.
 - Providers/GitHub Copilot: hash Responses replay item ids with sha256 instead of a weak 32-bit hash and build same-provider Copilot tool-call ids distinctly, so concurrent tool-call replays no longer collide and reject follow-up turns.
+- Agents/replay: normalize malformed assistant replay content before transport conversion while preserving empty-stop replay repair, so bad provider history no longer crashes with non-iterable content. Fixes #43795. (#82748) Thanks @IWhatsskill.
 - Providers/Anthropic-messages: extract `reasoning_content` from `thinking` blocks during assistant replay so proxy providers that route through the Anthropic-messages transport preserve reasoning context across tool-call follow-up turns. Thanks @Sunnyone2three.
 - Agents/GitHub Copilot: normalize replayed Responses tool-call IDs before dispatch so resumed sessions with historical overlong tool IDs continue instead of failing Copilot schema validation. (#82750) Thanks @galiniliev.
 - CLI/web: resolve provider-scoped web search/fetch SecretRefs for `infer web ... --provider ...` while leaving unrelated plugin secrets untouched. Fixes #82621. Thanks @leno23.

src/agents/pi-embedded-runner/replay-history.test.ts

@@ -126,6 +126,15 @@ describe("normalizeAssistantReplayContent", () => {
     expect(repaired.content).toEqual([{ type: "text", text: FALLBACK_TEXT }]);
   });
 
+  it("converts mid-turn zero-usage null stop turns to a replay sentinel", () => {
+    const falseSuccessStop = bedrockAssistant(null, "stop");
+    const messages = [userMessage("hello"), falseSuccessStop, userMessage("retry")];
+    const out = normalizeAssistantReplayContent(messages);
+    expect(out).not.toBe(messages);
+    const repaired = out[1] as AgentMessage & { content: { type: string; text: string }[] };
+    expect(repaired.content).toEqual([{ type: "text", text: FALLBACK_TEXT }]);
+  });
+
   it("preserves empty content with non-error stopReasons (toolUse, length) untouched", () => {
     // Boundary lock: only `stopReason:"error"` should trip the sentinel
     // substitution. `toolUse` and `length` are reachable in practice when a

src/agents/pi-embedded-runner/replay-history.ts

@@ -59,6 +59,7 @@ type ModelSnapshotEntry = {
   modelApi?: string | null;
   modelId?: string;
 };
+type AssistantReplayMessage = Extract<AgentMessage, { role: "assistant" }>;
 
 type ProviderReplayHookParams = {
   config?: OpenClawConfig;
@@ -355,7 +356,7 @@ export function normalizeAssistantReplayContent(messages: AgentMessage[]): Agent
       touched = true;
       continue;
     }
-    let assistantMessage = message;
+    let assistantMessage: AssistantReplayMessage = message;
     let replayContent = (message as { content?: unknown }).content;
     if (typeof replayContent === "string") {
       const normalized = normalizeAssistantReplayTextContent(message, replayContent);
@@ -368,7 +369,7 @@ export function normalizeAssistantReplayContent(messages: AgentMessage[]): Agent
     if (!Array.isArray(replayContent)) {
       replayContent =
         replayContent != null && typeof replayContent === "object" ? [replayContent] : [];
-      assistantMessage = { ...message, content: replayContent } as AgentMessage;
+      assistantMessage = { ...message, content: replayContent } as AssistantReplayMessage;
       touched = true;
     }
     if (Array.isArray(replayContent)) {
@@ -398,10 +399,10 @@ export function normalizeAssistantReplayContent(messages: AgentMessage[]): Agent
       // or completion and no content. Leaving other non-error empty-content
       // turns untouched preserves silent-reply semantics on every other code
       // path.
-      const stopReason = (message as { stopReason?: unknown }).stopReason;
-      if (stopReason === "error" || isZeroUsageEmptyStopAssistantTurn(message)) {
+      const stopReason = (assistantMessage as { stopReason?: unknown }).stopReason;
+      if (stopReason === "error" || isZeroUsageEmptyStopAssistantTurn(assistantMessage)) {
         out.push({
-          ...message,
+          ...assistantMessage,
           content: [{ type: "text", text: STREAM_ERROR_FALLBACK_TEXT }],
         });
         touched = true;