Well, the XDs came back today cleaned and lubed. The invoice said, "Tested extensively" with several types of ammo they named "with no malfunctions". "Suspect bad round".
Even though the local smith freed the thing up working the grip safety, they say no problem, so I have it back. No effort from SA to compensate me for my time or expense in sending it back either so I'm not very impressed.
I'll get out to the range soon and we'll put a few hundred rounds through it and see how it holds up.