The transfer bar is mechanically connected to the trigger & hammer, if it works some of the time theoretically it should work every time....theoretically... LOL.
Again with an empty gun, thumb the hammer back, the transfer bar should come up to at least 1/2 covering the end of the firing pin when at full ####. now with a small screwdriver or similar tool (pen will work) reach it in and push on the transfer bar, if it wiggles and moves up against the pin freely ( if you push it in far enough to push the firing pin, you should only notice a slight spring pressure from the firing pin return spring) it is probably going to work all right. Next, hold the hammer back with your thumb and pull the trigger, the transfer bar should now come up to almost completely cover the firing pin. continue holding the trigger in the firing position, now let the hammer come ahead slowly... watch the transfer bar, it should stay in the "up" position until the hammer reaches it. do not release the trigger yet, now look between the cyl and recoil plate, you should see a fair amount of firing pin protrusion into the area where the shell rim would be. Now release the trigger, you should hear a slight mechanical sound as the trigger spring returns the trigger ahead and withdraws the transfer bar. The firing pin should disappear back into its roost. If that is the case, all is well in that part of the gun it would appear to me.
Now getting back to my first post & your answer that you can't see any firing pin dents in the brass may be an indication that "over rotation" is still the problem but more pronounced than usually is the case. The cyl may be rotating enough past "lock up" far enough that the firing pin is hitting between the cartridges... so another test... Open the loading gate & rotate the cyl, do you hear a distinct "click" as each cyl ratchet notch is passed over the "hand". As well, you should feel a slight resistance when the cyl is rotated past each notch (from the hand spring pushing the hand against the cyl). This resistance is required to keep the cyl from a total free-wheel rotation as the gun is cocked. Without this resistance, the speed that the cyl rotates as you #### the gun can be faster than the locking bolt will come up to lock it.