Yes, they are both 40s and the spring looks the same, since I changed them recently, but no change in behavior from updating the spring.How does the recoil spring on the offending SIG look? Are both your Legions chambered in 40 S&W?
Agreed, I realize there are many potential issues that can cause feeding problems. I tried your test of sliding in a cartridge up the breach face, and while I get no visible brass shavings, it certainly does not slide easily under the claw, and once in there it will not be dislodged even when shaken pretty vigorously in any direction. Does that mean the extractor is too tight?To do a quick check of the extractor, remove slide, take a cartridge and slide it up the face of the breech from the bottom of the slide - this is the way the case base has to move as the cartridge is stripped from the magazine. The cartridge should move up the face with little friction which will increase some as the base groove moves under the extractor claw.
Once in position, the extractor should hold the cartridge with gentle shaking of the slide - but not a lot! Remove, and inspect cartridge case, breech face and extractor - there should be no brass shavings.
Feeding problems can be caused by several other things as well.
The problem with this approach is that there are a very few more obscure brands of ammunition where the FTFs are manifested, while working well with everything else, so the odds of them seeing the problem are pretty low. I can avoid the problem pretty well, I just happened to run across some ammo where I had a few FTF's so wanted to learn more about the problem, particularly with respect to the extractor...I had a minor problem with my P229 Legion, called Sig, got a RMA to return and had it back within two weeks. Let Sig take care of your Legion problem under warranty.