Having a hard time with this one...

New sysprep'ed image (win7) is really hit or miss post image with Windows Setup all too often flagging C:\WINDOWS\Panther\Unattend.xml as invalid. Some fail during the specialize pass others during oobe. If I boot with WinPE to take a look at the .xml the file has indeed been truncated. I've even found instances where the .xml exists but is empty. I opened the source image in Image Explorer and the .xml is intact/complete. I've never seen this before and I've been at it a while.

The image is coming from one of three SLES 11.2/ZCM 11.2.3 satellites via multicast to groups of 9-35 PCs of the same make/model and in the same location/vLAN. From the labs I've been in recently, I'm seeing the issue on 7/11 PCs, 13/24, 14/30, etc. Way too high. The rest in each group boot fine yet they all theoretically received the same bits.

The Tuxera driver is in play and this image did get a defrag/chkdsk before capture.

Any thoughts?