OK, I just tried a size "passthru" export encoding and got a "unsupported data" error on the PS3 with 2.1 firmware! I believe these files had previously played back in 4:3 format (literally 1440X1080 with no horizontal expansion) using previous firmware.
The coding times are so long it is difficult to run through all of the possible combinations in a reaonable amount of time.
The file does play back in 4:3 in QT player. Evidently, the 2.1 firmware either disabled 1440X1080 video or added a check to refuse playback with no anamorphic expansion flag set.
In a way it kinda makes sense that QT would play it because it has to support odd sizes such as that, whereas 1440X1080 non-anamorphic would not be a standard HD format.
I opened the file in QT-PRO and scaled the horizontal width as follows:
window-->show movie properties-->select video track-->visual settings-->uncheck "preserve aspect ratio" -->revise horizontal "scaled size" to 1920 -->file-export mp4-->options-video format "passthrough"-->save
The file now plays in 16:9 in QT, but still shows as "unsupported data" on the PS3.
from searching the web, I get the impression that the mp4 specification for horizontal scaling has somehow diverged from the original QT method. From there it seems to digress to people resorting to low level HEX editors to sort things out (good grief!).
reference---
http://forum.doom9.org/showpost.php?p=988006&postcount=2838
Actually, I am not sure why a scaling flag would even be required for true HD since there is no legitimate 1440X1080 4:3 aspect ratio format in the AVCHD spec
http://www.avchd-info.org/format/index.html