speaker sound issues, all dont sound the same but test the same?

My only thought is break-in... a small effect in most cases. I know how this will sound if you do it, but you break in a speaker by running it at high volume for a period of time. For woofers, a sine wave at resonance is effective at loosening up any tightness in spider or surround, but I'm unaware of any need to break in tweeters given their lack of excursion.

Have fun,
Frank

I would be guessing that it has to do with speaker/room interaction.

For example, around here when people post photos of their rooms showing off their big flash systems... you see an awful lot of rooms that have been badly set up. (acoustically) The TV screen may be located to one side of the room which forces one speaker to be in a corner up next to the side wall, while the other speaker is practically in the middle of the room nowhere near a side wall. If you were to measure the frequency response from each individual speaker, they would show a radically different response. That difference would also be very audible if you played a pink noise test tone through one at a time as well.

So it is not surprising for the same identical speakers to sound different when placed around a room. This is why some people go to so much trouble to rearrange a room that suits a more optimal speaker placement position first... rather than placing speakers to suit wherever the TV and sofa already happen to be.

What kind of test did the repair guy do? If he just ran pink noise through them, held up and SPL meter and got the same SPL between them all, that means nothing. They can still sound very different, even if they're equally sensitive. You need a frequency sweep to see where the tonal difference is.

And if the difference is in dynamic range and transient response - clapping - then FR sweep will show nothing as well... you may have very sensitive ears!

HAve fun,
Frank