Hate to say it, but you're chasing your tail on this. Once adjustments have been made on the SM, it's nearly impossible to get back to original settings. I've got the same exact set and my component 1080i is messed up. The picture flickers and goes dark/bright under 1080i setting on my Hisense HD off-air receiver. Switch it to 720p and it's flawless. HDMI is perfect on both resolutions as well but this box only does components and I don't feel like spending $50 on a component to HDMI coverter. The 720p looks just as good as 1080i to me.
If you still cannot admit defeat, there is a huge thread somewhere around here I used to fix the lower geometry part of my screen as it was bending in. It lists all the factory settings for our sets. However, someone said that each set is fine tuned at the end of the line by a tech so unless it's never been messed with, chance are it will never be like it was the day it was boxed up. But be careful, adjusting can get addictive. Get in, fix what you think needs fixing and get out. I've learned to accept what I have and just use what isn't giving me problems. These sets are special- they were way ahead of their time in design and function and there will never be another TV like them. Not to mention their picture is mindblowing.