Hmmm, strange, I'm running out of ideas on what the issue can really be. Normal Map compression issues maybe? Also, the seam in the last image isn't really noticeable, how bad is it when you apply the diffuse and other textures?
Somebody smarter may come and correct me on the particulars, but here's what's happening: UDK uses directional lightmaps, and to compute that directionality UDK has to establish some tangent basis for the surface. The editor does this based on whatever UV's are in channel 0 by default. So, if your doing any kind of texture…