John -
If it makes sparks at all, they are strong enough to light the gas. You might try opening up the gap a bit, to make a longer gap, but you can't open it very far before the spark will be unable to jump the gap.
My guess, from having gone through this, is that the spark isn't quite in the gas stream. The manual should show you exactly where the spark should be, and how long the gap should be. Or you could compare the location of the gaps on the failing pair to the location of the gap on the good burner.
You might also check the gas pressure. A thread yesterday on a different topic noted that the gas pressure in that TM was only about 6 inches of water column, where 11 inches is standard.
As for rack screws, hardware store screws are fine. I would opt for stainless steel screws.
Bill
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