Hey,
Doesn't sound too encouraging. Using channel 40 with 40mhz withw you are most likely doing eC so it could be worth trying channel 36 to see if it's a firmware bug which ideally will use Ce.
For testing you could try a 20mhz width, I know it's not as shiny as a 40 but you'll at least have double the spectral density in return and possibly a stable setup.
Since writing my initial response to you I've done further field testing and been lucky enough to learn from an industry insider that more or less write the book on WiFi implementation and the loudest comment I took from that was, stick with 20mhz. All my deployments now are 20mhz whether 5ghz or 2.