John,
Just to clarify, when I mentioned "another program", I meant another OUT file to load to the device. So, instead of loading Bootloader.out that was causing the problem, can you try loading another program? Are all OUT files causing the same problem under CCS5.3/5.4? How about standalone Flash Erase operations, do they work?
Also please note the suggestion that Ki suggest about switching compilers in CCS5.2. maybe this will enable you to continue development while we figure out the cause of the problem.
Thanks,
Ricky