the newer badlands packs do have zipper issues, they also have latch issues. we have several of the older 2800's and have never had a problem. there are times when loading mine and putting it on that I think "why isn't this thing exploding". the old ones are bombproof, if you find a used one, buy it.
i hope they get everything worked out because they are an awesome pack with a great warranty but I doubt they'll bring you new buckles or zippers when you're loaded with 60lbs of meat 10 miles back in.