There should be a setting in the service menu to turn the overscan completely off, which is the same as the "just scan" mode that was mentioned earlier. If turning this off does not fix the situation, then there truly is a problem. I'd get the service guy out there again and have him do that.
From a quick Google search it looks like that set had a lot of overscan problems. If Brandsmart is like Best Buy they may have a "no lemon" policy if a certain number of repairs are made, or there is a problem they cannot fix. I'd probably try and push for that.
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