I was going to post this a while ago, but I never got around to it. Seeing that other people are having problems with the new spyderco pivot screws I figured I'll add my input now.
I have a Para that I have been edcing since NewGraham got their second shipment in from Spyderco. First off I absolutely love the knife (I now see why the millie is so popular.) After a few months of heavy use at work I decided it was time to disassemble the Para so I could clean and lube it real well. In the meantime I have read a lot of posts concerning the vertical blade play on the Para. One of the solutions offered was to tighten the pivot pin. Since I have owned this knife there has always been the most minimal amount of vertical blade play... so I figured if I tightened it a little bit it would solve the problem. Well, I slowly started to tighten the pivot the head twisted right off!! Honestly, I did not even torque it, I went as slow as possible checking to see how easily the blade would move out of the handle.
I called the warranty dept. and left a message and about a week later they sent me another pivot but only the female end!?! I clearly stated in my message that the screw broke off in the pivot and that I needed the entire assembly. No big deal, I used one of my left over Dodo pocket screws and now the Para is back on duty 24/7.
My assessment of the problem (and maybe because of your experience as a machinist you will agree/disagree) It seems to me that when the broaching process is completed there is not much material left connecting the thread to the head of the screw, making it weak. Sorry for the long winded post.