Well, TI never helped with this, and we noticed that the newer versions of firmware are even more sensitive to bad blocks.
In fact, TI's instructions for loading newer versions of firmware include using the "NAND scrub" command which causes warnings to be issued from uBoot that this will damage factory bad block info. Doesn't seem like a good idea. Not sure what the exact reasoning for this is... whether it was more expedient for firmware development, or to work around some bug, but it seems scary for production.
Currently we have a really impractical solution of screening the NAND chips for bad blocks, grouping them into different batches, and using one of several different layouts for the memory images to avoid the bad blocks in the areas that the firmware apparently can't tolerate.