diff --git a/verl/utils/megatron/router_replay_patch.py b/verl/utils/megatron/router_replay_patch.py
index c618608801f..328b93f99dd 100644
--- a/verl/utils/megatron/router_replay_patch.py
+++ b/verl/utils/megatron/router_replay_patch.py
@@ -22,9 +22,10 @@
         compute_routing_scores_for_aux_loss,
         group_limited_topk,
     )
+    from megatron.core.transformer.moe.token_dispatcher import MoEAlltoAllTokenDispatcher
 except ImportError:
     warnings.warn("NPU not support router replay for now.", stacklevel=2)
-    pass
+    MoEAlltoAllTokenDispatcher = None
 from megatron.core.transformer.moe.router import TopKRouter
 from megatron.core.transformer.transformer_config import TransformerConfig
 
@@ -343,7 +344,34 @@ def patched_init(self, *args, **kwargs):
         if self.config.enable_routing_replay:
             self.router_replay = RouterReplay()
 
-    # Step 4: Apply the patches
+    # Step 4: Patch MoEAlltoAllTokenDispatcher.preprocess to handle router replay
+    # When router replay is enabled, duplicate indices in top_indices can cause
+    # routing_map.sum() < num_tokens * topk, leading to split size mismatch in alltoall.
+    if MoEAlltoAllTokenDispatcher is not None and not hasattr(MoEAlltoAllTokenDispatcher, "_preprocess_patched"):
+        original_preprocess = MoEAlltoAllTokenDispatcher.preprocess
+
+        def patched_preprocess(self, routing_map):
+            """Patched preprocess that handles router replay correctly for alltoall dispatcher."""
+            # Call original preprocess
+            result = original_preprocess(self, routing_map)
+
+            # Fix num_out_tokens when router replay is enabled
+            if (
+                getattr(self.config, "enable_routing_replay", False)
+                and not self.drop_and_pad
+                and self.config.moe_expert_capacity_factor is None
+                and not self.config.moe_router_padding_for_quantization
+            ):
+                # With router replay, duplicate indices can reduce the actual routed
+                # token count, so derive it from the routing map instead.
+                self.num_out_tokens = int(routing_map.sum().item())
+
+            return result
+
+        MoEAlltoAllTokenDispatcher.preprocess = patched_preprocess
+        MoEAlltoAllTokenDispatcher._preprocess_patched = True
+
+    # Step 5: Apply the patches
     TopKRouter.__init__ = patched_init
     TopKRouter.routing = patched_routing
     TopKRouter._router_replay_patched = True