So the issue has to do with exporting the high via GOZ from zbrush to max, i found that if i export an obj form zbrush then import it to max and bake it works fine.
I agree with zacD Try exporting it as a FBX File, maybe you will have a better luck with it, I use FBX to export from 3DS to UDK with the following option selected
I can't remember what Max has, but in Maya when you export as a FBX, there's an option in the 'Geometry' checkbox to Triangulate when you export. I'm pretty sure it's on by default.
What are your MD export settings? You can export welded quads. Those orange dots are not verts, they are from the Control cage of the dynamic subdiv that you have turned on.
You need to export the object into separate chunks, with each chunk having a separate material. In Max, I believe that you select all your objects and then> export selected> as .obj
from in the project shelf, right click > export resource. it export by default in png 16bit. I got the same problem also with plain normal map, there is always this grainy effect.
Yup, Xnormal installs an export format called SBM that can export your low poly with its cage. It's slightly weird that it will only work if your model is an edit mesh.
It's totally possible, in matinee you can import/export a sequence as a FBX file. More infos here : http://udn.epicgames.com/Three/MatineeUserGuide.html#Exporting%20and%20Importing%20Matinee%20Data