This problem sounds very familiar - I had similar issues with a 440 last year. My gripper was almost totally locked up from old gunk and sitting for years. I followed much advice on getting it freed up and to where everything seemed to be working normally. Still, I was plagued with little issues that always pointed to either the cam switches being out of adjustment or the shaft gears being out of sync.
You may have already done this, but I've read through all of the posts in this thread and I don't see where you've actually disassembled the gripper assembly. Taking the gripper completely apart, then cleaning and lubricating it properly was the only way I managed to solve my problems. From your description, it sounds like your issue may be in the internal workings of the gripper, in particular the trunnion that actuates the inner gripper (which moves independently). Since this unit is internal, you can really only get to it by taking it all apart. It's not as bad as it sounds and I was able to complete in less than an hour with the mech in the cabinet. Just make sure you have the parts breakdown diagram from the manual so you can keep track of everything. AND don't get over zealous driving the pin out of the reversing cam or you'll spend most of your time looking for it - Yup, that was me
Nelson