Well the Guy that you are talking about in the older outfit he looks like hes got a republic symbol on his sleve and the later version doesnt however I never played the Sith Warrior up to that part in the game so I dont know if it would make sense for him to have the shirt/armor

Well yes I suppose

You can but you dont have to in order to get him a second time you can buy him through legacy but it costs 1000000 credits per character

Well this is good to know That im not the only person that has this problem it's annoying that this happened about 15% or more havn't been transfered to the APAC servers.