drdrake:macuser: New firmware available for Sony 4K Android TV's http://www.sony.co.nz/support/download/607113/product/kd-49x8300c
Macuser - Thanks for the heads up! 😀
New firmware installed plus a full factory reset to remove any gremlin settings that might be lurking. The issue isn't fixed but it has definitely improved. Although the release notes made no mention of an audio fix and it could just be a coincidence, progress is still progress.
I would estimate the audio delay at around 100ms now, based on visual comparison from a calibration disk and the echo test using both TV speakers and amplifier via digital out. That makes the error negligible during dialogue and for most other soundtrack elements. But it is still apparent for abrupt or percussive sounds, such as a gunshot, door slamming or someone being slapped across the face.
I intend to keep talking with Sony for now. Hopefully they can keep working to resolve the issue.
EDIT: I decided to use a shot timer (as used on a pistol range) to try get a more accurate handle on the split time between audio signals when generating an 'echo' through TV speakers and amplifier. Set an AV sync track from a calibration disc at loud volumes, then I added even more audio delay using AV sync on the amplifier (an extra 300ms) to be sure I could time both signals consistently. Then subtracted the extra 300ms from the average split time. The result averaged 30-40ms. As previously mentioned, still noticeable for some situations, but now 99% tolerable.