What POD(s) is necessary to produce a Prussian state split between Germans and Poles, the way Belgium has French and Dutch speaking populations?
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If Prussia keeps its 1795 borders, or something close to that situation, the demographics of the area may produce a state with two or more linguistic communities.
 
No napoleon/early defeated france or prussia survives the revolutionary wars with their territory intact, i can imagine they would keep their polish territory maybe even adding Cracow someone in the post revolutionary consensus, rhineland can be austrian or independant, so when 1848 come, prussia just got their side when germany unify itself.
 
How did the Prussian state govern its polish territories between 1795 and Tilsit?

They heavily invested in those territories because of their potencial, it was one of the areas of the kingdom where they invested the most during the period of Prussia rule which was why they wanted good compensation in 1815, and, if I remember this correctly, ruled there like in Silesia, appointing locals to the bureaucracy, tried to keep good relations with the Catholic Bishops, etc...overall they ruled those lands like any other part of Prussia.
 
You need to prevent OTL Congress of Vienna, which means preventing the loss of significant portions of post-Partition Poland to Russia, and also prevent them from gaining most of the Rhineland; to do that means altering the great powers diplomacy, Prussia as the weakest basically took the Rhineland because they were told to do so and because no one else wanted those lands (and the burden of guarding against France) nor France to get them. There are basically two PoDs-
1. avert the revolution, or end it quickly, preventing the massive map redrawing; or
2. make the Revolution successful, whilst preserving Prussia- best way is to get Prussia to stay out of the initial war and ally Napoleon a la Bavaria, gaining Saxony and a free hand in Poland and building a Baltic empire.

Prussia at this time was very much a composite, multi-ethnic state, one which only post-Vienna was at all interested in Germany beyond the Baltic/Pomeranian coastline. Keep Prussia focused east and out of the Rhineland in any significant capacity and they will naturally tend to evolve into an Austria-Hungary style dual monarchy stretching along the Baltic coasts, assuming they aren't defeated and carved up by Sweden/Russia/Austria of course.

Alternatively one could angle for a Brandenburg-Polish union a la Wettin Saxony, which is hardly impossible at any time in the 16th, 17th and 18th centuries.
 
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