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Sear failing on T/C HAWKEN

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I've got similar problem with a T/C renegade, at half cock you can push the hammer all the way down against the nipple and even at half cock you can pull the trigger with the trigger set and the hammer will come down on the nipple. I've took it apart and cleaned it and compared it to another lock and can't see any difference in the sears. Any suggestions?
 
Hats off to TC/S&W. They sent me a prepaid shipping label and the rifle was returned in 4 weeks with note 'Evaluate/Repair replaced tumbler'. There was no charge. Don
 
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