That truly is a head scratcher. Maybe with a little more information, an answer can be found. On your lock, does the sear bar return to exactly the same position in each position (i.e... In forward, half-cock and full cocked)? Is there a possibility that perhaps when you think that the bar is hitting the sear, it is in fact, not actually doing so? I ask these things, wondering if it is possible that perhaps the trigger bar is somehow not below the sear when cocked in the manner you describe. Just throwing out an idea, since this is a tough one.
Matt