FINALLY.... I fixed it!
Ok, so I did some internet scouring to find the fix to this problem - took me quite a while - this was probably easily the problem that has taken me the longest to diagnose and fix.
I wanted to give credit to the website that finally helped me get my gears going, but unfortunately I can't find it anymore. If I find it, I'll post it in hopes it'll help others down the road.
My problem was exactly what PostMaster had with his old TFTC in this previous thread:
So, what was my problem? My ball launching switch was bad/old. Just to clarify, that switch is 90 degrees from the launch solenoid (this solenoid shoots the ball INTO the shooter lane, I am NOT referring to the door handle shooter solenoid). In the TFTC manual, it is on page 50 - item # 22 part # 180-5119-00. That switch was just old and beat to heck. What was happening was the coil that has the bracket bar that allows balls to move through the trough during multiball was too fast for the launch switch, so everytime multiball occurred, one extra ball basically got through the bracket bar, and the switch in essence, couldn't keep up. At least that's my understanding so far.
So, if you put that part number in any pinball website search engine, you're going to get the ball trough roller switch - which not only has the incorrect arm extension (the wrong switch has a roller ball on the end and not the triangle shaped arm you need), but it also has the incorrect mounting holes so you couldn't even install the cross-referenced switch if you wanted to.
So, what do you do ? You install this switch: http://bayareaamusements.com/Merchant2/merchant.mvc?Screen=PROD&Product_Code=SW-180-5034-00
It will read as a "Data East ramp switch" - now I don't know exactly what "ramp switch" is to suggest, as I didn't see it ANYWHERE in TFTC's manual, but trust me - it works just like the previous switch - triggered the switch is closed - untriggered the switch is open, and it does the job it is supposed to do.
Now, if you install that switch, you'll have to make one small modification. Take some wire cutters and clip the very very end of the arm right after the triangular bend. If you don't, that part of the arm will catch on the ball trough, and the switch will not function correctly. Just clip the end of the arm so the full triangular bend is the VERY end of the switch arm, and you'll be good to go.
Install the switch, putting the wires exactly in the same locations that they were on the previous switch. All the male spades are in the exact same places, so it should be a plug and play job - take pictures if you don't think you'll remember which wires go where; I know I took pictures.
The balls launch SO much faster with this switch. It was like - not a whole new machine - but it was like if you took your stock engine and installed a turbo on it - just a great feel and a wonderful improvement.
Anyhoo, hope someone somewhere down the road benefits from this post. Life is Good