Hi All,
Thank you for the suggestions. The issue for the ball launch was indeed the plunger tip alignment to the pinball. It was quite off actually and I had to loosen up the assembly and shim up the bottom of the mount (outward, facing the player) so the plunger would hit the ball center (top to bottom) and shift the whole thing to the left so that it was centered left to right. If I pull back the plunger and snap it just a little it makes the loop every time! I'm glad to see this fixed as it was wearing very thin with us.
Now the next thing is the ridiculous center ball drain when making the center loop shot and it comes down the right loop straight into the $hitt3r.