Shaon – I gave that a try and it did not resolve the problem.
When I had both options disabled (resumable downloads, output buffering) – it would download a 0kb empty zip file with the name of the original file.
When I disabled only Output Buffering, it would download the entire file, but it gave the same error – none of the zip files were able to extract.
When I disabled only Resumable Downloads, it would download part of the file, but again would have extraction issue because it did not complete the entire file (for example, with a 1.4GB file, it only downloaded 674MB but said the download was done.)
So – any ideas? It seems like something is corrupting the download. Do you think it’s because Download Manager is having trouble with large files – all the zip files I’m having issue with are 1-2GB in size? Has this come up as an issue before?