I did compare struck primers and ones that fired successfully in DA out of the PC gun seemed to exhibit no difference from the other 686. The FTF's seemed like light strikes and the rounds that did not fire in DA on the PC gun did fire on second strikes. Of course I had to wait for possible hang fires, and when it was doing that 2-3 times per cylinder, it got real annoying fast.
I also looked at the firing pin protrusion on both guns prior to sending the gun in, and they looked the same.
The difference I noticed on the PC gun is that in double action the hammer on the PC gun falls noticeably earlier than on the other gun. Mr. Borland pointed out that the gun may be designed to do that so it fires more quickly, seeing as it is a competition gun. That seems reasonable given that the work order did not list any replacements of trigger or sear components. The hammer still falls earlier than on the other 686 after coming back.
This is a guess only, but it seems to me that the failure to fire is a combination of factors. The trigger action is very smooth from the factory, as expected. I assume that means extra stoning of the contact surfaces happens at the factory, like I'd expect on any PC gun. The mainspring is also bossed, which as I understand will result in a lighter pull. This is also evident when pulling the trigger. However, it seems the combination of smooth and light was resulting in a standard firing pin not making positive enough strikes in DA due to the reduced hammer travel distance. In that context, it makes sense that the only way to create a more positive strike, without totally changing the trigger pull to a more standard trigger feel (not that there's anything wrong with S&W triggers) was to install a slightly longer firing pin.
In comparing it to the other 686, it is in fact a hair longer. Of course, I haven't gotten a chance to even test it yet, so we'll see if it worked or not.
Again, the point here was to learn. Sending it in was really the intent from the beginning, and besides gas money, this has cost me nothing. The gas money wasn't even an issue; it just meant I did some shopping off my normal "go to the city" schedule.
If my thoughts on why the new firing pin corrected the issue are incorrect, someone else please chime in.