Hi -
I have been converting alias wire files to IGES and taking them to MAX from a considerable time now and have not experienced any major problems so far. Following are some of the points you can consider -
1. Delete construction history of your models.
2. As far as possible, do not use multiple trimmed surfaces.
3. Try stiching your surfaces.
4. Delete all unwanted geometry, curves, lights and null nodes, you can keep specific files only for data transfer.
5. One of the ways can be convert your models into poly & then export as DXF as well.
IGES with 5.3 works best for me all the time from Alias.
Hope this helps. Good luck !
Anand Joshi.
Alias Certified Instructor.