Yep, I had that happen. For me it was the spring that holds the safety bar down...I put it together wrong when I took it apart and swapped two springs around...I doubt that is what happened to you...but the spring may be bad. With the hammer back, pull the bar up and see if it feels loose. It should spring back when you let go. Don't fire it too much like that or you may ping the tip of the bar or the lip of the recess that the bar falls in.
As for sending the gun in...I sent in a 97 that I screwed up and I got it back (with an action job also) in 3 working days, that includes the day I sent it....I did have to pay for the repair, but that's because I messed it up....they are quick on repairs!