Hi,
User M del Mar and me belong to same investigation group, so the problem is common. We have 116 subjects and we detected this trouble. However, we tried to repeat the make_average_subject command using a subgroup (only 60 subjects) and label files were correctly created. Maybe, number of subjetcs is the key. Nevertheless, with Freesurfer 5.3 we haven't this problem, no matter number of subjects.
Best,
Sofia