Nick
The 4MHz oscillator is a trimmed RC oscillator with a certain amount of tolerance. It may be that the trimming accuracy is varying and so some chips have less accurate baud rates which causes some unreliability, whilst others allow better performance.
In applications requiring reliable UART operation (especially over extended operating range) it makes sense to use a crystal source rather than the RC oscillators, or look into additional factory trimming to achieve a more suitable baud rate result.
Regards
Mark
uTasker developer and supporter (+5'000 hours experience on +60 Kinetis derivatives in +80 product developments)