Eric, I nailed this down to at least give you a starting point of where to look:
Password Length set to 35
No leet
HMAC-SHA-256
URL Contains: .google.com/
Use URL: google.com
I simply copied the default character set and pasted it at the end of itself to produce an incorrect password length. I then used the half-split method, until I hit upon the magic number of 180 characters that produce a good result - anything more produces a password that is one character short:
Character set length = 180
ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz0123456789`~!@#$%^&*()_-+={}|[]\:";'<>?,./ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz0123456789`~!@#$%^&*()_-+={}|[]\:"
PW: OK
CYY_FFQT,&?C9QSU-`v{o}v%ehl{J#{&u:& = 35
Character set length = 181
ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz0123456789`~!@#$%^&*()_-+={}|[]\:";'<>?,./ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz0123456789`~!@#$%^&*()_-+={}|[]\:";
PW: WRONG
;!Ut$(MkhV*^
[email protected]%Dv2*<#SL = 34 - off by one
Next, I tried just alphanumeric characters, to see if maybe it had anything to do with the non-alpha-numerics, but this produced the same results (180 character max).
I did play with even larger character sets, and the resulting password length gets even shorter, so the bug seems to be compounding.
I hope this helps...