Since you have eliminated everything else, I would suggest trying the fiber washer idea between the roller assembly and the bottom of the truck and see what that does, it is an easy enough thing to try. If it doesn't work easy enough to roll back, and maybe putting a bit of a gap will make the rollers contact the rail more. I did a search on the forum and arcing/sparking between the pickup rollers and the track seems to be one of the more common topics , even more than people wondering when trains are going to become cheaper, made in the US, not have so many defects, die or not die, etc *lol*. It seems like sometimes there are engines that simply love to spark, the way my pretty boy numbskull dog seems to revel in finding things to bark at
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