When Model Merging Breaks Routing: Training-Free Calibration for MoE

Model merging has emerged as a cost-effective approach for consolidating the capabilities of multiple LLMs without retraining. However, existing merging techniques, largely based on linear parameter arithmetic or optimization, struggle when applied to Mixture-of-Experts (MoE) architectures. We identify a critical failure mode in MoE merging, termed *routing breakdown*, in which the merged router fails to dispatch tokens to suitable experts. Routing breakdown stems from the sensitivity of the non-linear softmax and discrete Top-$k$ routing mechanisms to parameter perturbations from merging, a sensitivity further amplified by load-balancing constraints imposed during MoE pretraining. Because fine-tuned experts exhibit distinct specializations, even modest misrouting can cause severe performance degradation. To address this issue, we propose Hessian-Aware Router Calibration (HARC), a training-free framework that leverages second-order curvature information to realign the merged router. This approach admits a closed-form solution that can be efficiently solved using a matrix-free conjugate gradient method. Experiments on mathematical reasoning and code generation tasks show that HARC effectively mitigates routing breakdown across diverse MoE merging baselines and leads to substantial performance improvements.