Does the product issued from stock to be repaired have the exact same serial no, lot/batch no, w/d/r no and condition code as the most recent as-built structure for the same part and serial?

Yes to all, the one difference is the revision #.  When it was originally made on its own shop order it was part/product structure revision 1.  When I processed through its first multi-level repair shop order the part/product structure was at revision 2, and it went through fine.  It updated the part serial record to revision 2.  This latest shop order is also for revision 2 and won’t work correctly. I thought that might be the problem so I tried to using revision 1 again and it doesn’t work correctly either.