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@MrMister
Right, I think (think) I've worked out what's going on. The pivot boss (which can be unthreaded and removed) doesn't appear to fit the Shimano pivot arm (it is maybe 2-3mm proud when screwed all the way in, meaning that the pin doesn't engage). I've found a handful of examples of similar situations online but no definite answer as to how to resolve this. I could buy a replacement boss, but presumably this will be the same size as the current one (I guess m10 x 1.25) and therefore won't help.
Anyone have any ideas to prevent me from sobbing uncontrollably into a greasy rag?