Hi Flap.. OK then.. we'll wait and see. Please post back when you get a chance as to the findings... It sure sounds like you've done everything by the book.. It must be an internal component as you said, that might have either been installed incorrectly from the factory, or faulty from the factory. One of those "anomalies" it seems. haha..
Hopefully we can learn.. sorry it might be at your expense this time.. but I'll pass it forward sometime soon I'm sure. Have a great weekend.