Seems that a remote data source is being preferred to known local data (Routes table in DB) just like the overwritting by photgraphic sourced data of the GATS aircraft information.
No, I don't think it's a routes lookup problem.
The route being displayed in the pop-up for BAW909U is actually the correct route for BAW820, where the hex codes for the two aircraft operating those respective flights differ by only one bit.
Clearly, as Tarbat says, hex codes are getting corrupted somewhere along the line - the question is whether this is happening in the course of the transmission, or after the packet has been received by John's RB. I suspect the latter, given that there are few, if any, reports of similar problems from anyone else.
If I were in AirNav's shoes, I'd offer John a box swap, if only to troubleshoot the problem.