Wow, I seem to have started a rash of knee issues, sorry for the push into the pain zone. Joe, I hope you can figure your problem out, it hurts me to see one of the real mile and altitude eaters here down from an injury or problem. The lnly thing i found when I had my problem a few weeks ago was that my seat had gotten raised from my usual setting, probably during some maintenance when the seat and post were taken out and cleaned so carbon assembly paste could be applied. I guess I didn't measure when I reinstalled it and left it high. The idea about checking the fit over again sounds like a good one, the cleat being in bad shape set off an alarm for me, too. Best of luck.

Bill