I have read here and elsewhere the crack issue should be resolved by lower torque in manufacture process. I've not read anything about the fans though. Interesting that it isn't gaining more attention.
Mine had the captive washers, so they should have been the updated version. I dont think they actually fixed the case cracking issue but maybe I just got unlucky four times
I think the fan noise is always going to be an issue with these lights- high output with a small lightweight heatsync. Fan noise was a complaint with previous generations too.