Here's a screenshot of the Prime test running. This one didn't run for long as I just did it to take a screenshot. But you can clearly see the 4th core isn't running. The tests I ran last night went on for much longer and the 4th core didn't complete a test in any of them.
I did try that OCCT program too but it didn't find any errors. Not sure what's going on there. Why would in not work in Prime but be fine in OCCT?
I did some further testing with Cinebench GPU test, playing around with the affinity of the cores to see what happened.
All 4 cores on = Poor performance
Cores 1,2 and 3 on = Normal
Cores 1 and 2 on = Normal
Cores 1 and 4 on = Poor performance
Also, while that 4th core was enabled the GPU usage shown in GPU-Z was pretty much 0% the whole time. There were a few small spikes of usage but very low(5%) and a good few seconds apart. On all the tests where the 4th core is disabled I get a nice constant usage of around 50%, with no dips or spikes. So that 4th core is clearly interfering with the CPU > GPU.
I did also pull everything apart again this morning and checked the CPU socket and CPU pins. All seemed ok. Although, with all this messing about I'm lossing a little of the thermal paste between the CPU and heatsink. I'm pretty sure there's still good contact though as the two still stick together quite tightly and there's no visible gaps or holes in the layer of paste.
I've got a mate who I think might have an AM3 mb so I might try and get round to his at lunchtime to see if we can do some testing. If I can try my CPU on his board and vice versa then it should be fairly clear where the problem is.