My punch kit arrived today and I went ahead and punched out the pin holding in the extractor assembly. Sure enough, with the extractor out brass slides in/out of the barrel freely. Just a little friction in the final seating, but the extractor would pull it past that easily. Bottom line the issue is clearly the extractor pin, not the barrel.
I will call T/C back tomorrow. I'd sure like to avoid sending my barrel back and losing it for 3-4 weeks.