Yes, size deviations definately occur. I can order the same size 4 jeans from Gap, and one may fit, but the other is too tight. Same style, same brand, etc. I even asked a Gap clerk about it, and she said, "oh yeah, you HAVE to try everything on, because they each can be so different, even if it's the same style and size". I LOVE Athleta, and along with their great workout clothes, they have great customer service. Just call them and tell them what happened. I bet they take care of you right away.
Becky
Becky