I dont know if this helps, but when i need to test joysticks, (buttons or axis), i use a little and very usefull program, named Diview. It has only 40k, and you can google it and download, i think its freewear program. i often hack game-pads to do more precise controllers, and all the testing is done with this tool, including the buttons. Connect your joystick/controler and test the butons. It is also way much better for axis callibration than the windows program, because you can insert the maximum, minimum and midle values, and also input dead zones etc. I never had this caind of problem you have, so i can not help more, sorry. Can it be something burned on the electronic board? Or some plug disconnected? ...
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