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Seeing as you've been pretty comprehensive in your troubleshooting and both Digi and Apple have helped you out with their own systems, my guess would be that there's a third-party plugin problem.
If even one plugin is installed on your PT system that is not up to date/has bugs, it can kill the whole setup. Try taking everything out of your plugin folder, reintroducing them one by one and building up sessions with each to see if there are any issues.
The only other thing I can think of is a dodgy MacPro.
Good luck!
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-Dmitri Shostakovich
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