That was the sound of me shooting myself in the foot. I did an asterisk upgrade from 1.4.0 to 1.4.18 last night, and I tested almost everything. The one thing I missed was an IVR that plays a brief intro message and then drops to the main IVR. There is no prompt (or time) to enter a keystroke in the first short message. It's just there to give the customer an easy way to add an announcement to their greeting without having to re-record the whole main recording.
Well, I found out this morning that it was playing the first recording and then failing. Scratched my head about it for some time. Then, I remembered Alex telling me some time back to set autofallthrough=no in extensions.conf. At some point along the way the default for authfallthrough becamse yes. That caused me a lot of grief today, so I thought I'd pass it along.