Marquee tool feathers when its not supposed too

Question

I just started working at a new print shop so not sure if this is a feature that was added in CS4 or if it something in the preferences.
My issue is this. When working on window designs (perforated vinyl), I bring my illustrator template into photoshop at 1000dpi as a work path (1/10th scale) I do my designs, then flatten the layers and drop my dpi to 100, go to my work path and command+left click to highlight. The next step is minusing part of the path (think 2 windows, one on top and one on bottom) so that my marquee only selects the top window. I then expand by 100pixels (for the bleed) and copy paste into a new document.
This worked perfectly on CS2 and I believe CS3 as well. Something has changed and I am not sure if this is a bug or what. I have put a screenshot of my copied/pasted layer below so you can see.
My main concern is two fold. 1, the marquee clips in a diagonal direction (this is fine, it did this in the past as well) #2 however is the feathering. As you can see the left side is feathered (which is weird because the right doesn't feather) but the bottom and left sides feather. Top and right side are fine.
This is the most annoying thing I have had to deal with. Please someone tell me why this is happening.
PS. As a designer with more then 10 years in this field I BEG OF YOU ADOBE!!! PLEASE STOP PUTTING OUT NEW SOFTWARE UNTIL YOUR OLD ONES ARE 100% FIXED!!! :end rant:

Answer 1

Thank you for the helpful suggestions.
To Zeno - I did check the feather selection (im on a mac though, so its command click) and the feather is set to 0.
To Mylenium - I am a bit confused as to what Illustrators "pixel grid alignment in AI" is. Also, since this is a smart object (retaining vector capabilities in PS) why would anti aliasing come into play? It was always my understanding that PS treated smart objects as vector and that anti aliasing is considered a raster effect.
I think this is a bug for 1 simple reason. The left and bottom are feathered, yet the right and top sides are not.
Any other suggestions? I am all ears. And again, I appreciate you two taking the time to give your helpful input.
Thanks!