I remember a particular problem once with HCT564's (flip-flop's).
Production 2nd-sourced what was supposedly an exact replacement part. Turns out, the 2nd-sourced part had slightly better static discharge performance than the original, but was otherwise identical in every respect (at least on paper).
You guessed it: IT SIMPLY WOULD NOT FUNCTION in the target hardware. (Not function weirdly or erratically, some of the time. Would NEVER work!!) It took a while to figure this out.
As to why so long? "Hey", it's a '564. How complicated can it possibly be?!