I was thinking about a corrupted flash content (unfortunately I know that problem very well at work), not a bad chip. Flash are prone to such problems when during either a block erase cycle or a write cycle, there is a voltage transient of some kind or some other problem and you end up with a sector written with incorrect data. It has to be handled as much as possible by the firmware itself, but it's not always doable. But you're right, it's more likely an issue with the CPU itself and if you have already reflowed it once without success it might an unrecoverable solder ball crack or even a problem with the die itself in the package (don't know if it's a wire bond or not)
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