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[BUG] Next.js 16.2.0 crashes on Cloudflare Workers (Error 1101): Unexpected loadManifest(/.next/server/prefetch-hints.json) call! #1157

@dulapahv

Description

@dulapahv

Describe the bug

After upgrading to Next.js 16.2.0, the Worker crashes on startup on Cloudflare Workers with Error 1101.

Exception:

Unexpected loadManifest(/.next/server/prefetch-hints.json) call!

Log from Cloudflare Workers:

{
  "message": "Unexpected loadManifest(/.next/server/prefetch-hints.json) call!",
  "exception": {
    "stack": "    at loadManifest (worker.js:34905:15)
	             at NextNodeServer.getPrefetchHints (worker.js:76154:142)
				 at new NextNodeServer (worker.js:75898:114)
				 at .open-next/server-functions/default/handler.mjs (worker.js:76914:18)
				 at __init (worker.js:11:56)
				 at worker.js:80972:43",
    "name": "Error",
    "message": "Unexpected loadManifest(/.next/server/prefetch-hints.json) call!",
    "timestamp": 1773864444280
  },
  "$workers": {
    "event": {
      "request": {
        "url": "https://test-cf.dulapahv.workers.dev/favicon.ico",
        "method": "GET",
        "path": "/favicon.ico"
      }
    },
    "outcome": "exception",
    "scriptName": "test-cf",
    "eventType": "fetch",
    "executionModel": "stateless",
    "scriptVersion": {
      "id": "65bfbf94-2bd5-46dd-8e80-f88daa8b89f7"
    },
    "truncated": false,
    "requestId": "9de6dd08bf0eb384"
...

Works with Next.js 16.1.x (downgrading avoids the crash).

Minimal reproduction repo: https://github.com/dulapahv/nextjs-16-2-open-next-cloudflare-loadmanifest-crash

Steps to reproduce

  1. Deploy a Next.js app to Cloudflare Workers using @opennextjs/cloudflare (OpenNext).
  2. Ensure wrangler has nodejs_compat and global_fetch_strictly_public enabled.
  3. Upgrade Next.js to 16.2.0.
  4. Build & deploy.
  5. Request / -> Worker throws Unexpected loadManifest(/.next/server/prefetch-hints.json) call! and Cloudflare reports Error 1101.

Expected behavior

The Worker should start and serve requests normally (e.g. GET / returns the page) without throwing a startup exception.

@opennextjs/cloudflare version

1.17.1

Wrangler version

4.65.0

next info output

Operating System:
  Platform: win32
  Arch: x64
  Version: Windows 11 Education
  Available memory (MB): 32620
  Available CPU cores: 16
Binaries:
  Node: 22.16.0
  npm: 11.4.1
  Yarn: N/A
  pnpm: 10.30.0
Relevant Packages:
  next: 16.2.0 // Latest available version is detected (16.2.0).
  eslint-config-next: 15.4.6
  react: 19.1.5
  react-dom: 19.1.5
  typescript: 5.9.3
Next.js Config:
  output: N/A

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