This was over a week ago, and I had mostly given up and decided to wait for a patch, but decided to try again anyway. Two days ago I cleared my cache, installed the game to my hard drive, turned off autosave, downloaded the latest patch again, and when it started I didn't get an error on the menu screen. All the saves I had after going back into the Vault with Cass were still corrupted (1 worked but every save after playing it wouldn't load), but the ones from before I went back were somehow working again. I loaded one up and continued playing, saved and loaded with no error. After getting 2 hours of progress I save and load and its fine, but after turning on my xbox again later, I got the "some of your downloadable content is..." message and the new files were getting the DLC error again. I cleared my cache again, downloaded the patch again and this time they loaded normally. I have been playing for a while now without the DLC error coming back. I'm not sure how much vault 3 has to do with this bug because the point where I dug myself out was after I had gone in once already, and I still have motor runners helmet stuck in my inventory permanently as of now. Maybe I got really lucky, just doing random things and now my game works, but having a lot of saves to fall back on definitely helped for me.
