Make the attached patch to libmilter, rebuild your library and then relink dkim-filter, and let 'er rip. This will log a message for every piece of I/O between the filter and the MTA so the increase in your mail log could be substantial, and will also log a message if a milter callback returns a non-standard value (which skips the reply, which may be the problem). Unfortunately it looks like this is the best next step to isolating the problem.

Talk to you in about a week, right?  :-)

Thanks for trying this out.

-MSK
Index: comm.c
===================================================================
RCS file: /cvs/libmilter/comm.c,v
retrieving revision 8.67
diff -u -r8.67 comm.c
--- comm.c      2 Nov 2006 17:54:44 -0000       8.67
+++ comm.c      10 Apr 2008 23:21:40 -0000
@@ -197,6 +197,10 @@
                        /* makes life simpler for common string routines */
                        buf[expl] = '\0';
 #endif /* _FFR_ADD_NULL */
+
+                       smi_log(SMI_LOG_INFO, "mi_rd_cmd(%d) on fd %d", *cmd,
+                               sd);
+
                        return buf;
                }
                i += len;
@@ -353,6 +357,8 @@
                iovcnt = 2;
        }
 
+       smi_log(SMI_LOG_INFO, "mi_wr_cmd(%d) on fd %d", cmd, sd);
+
        l = retry_writev(sd, iov, iovcnt, timeout);
        if (l == MI_FAILURE)
                return MI_FAILURE;
Index: engine.c
===================================================================
RCS file: /cvs/libmilter/engine.c,v
retrieving revision 8.162
diff -u -r8.162 engine.c
--- engine.c    27 Feb 2008 01:34:14 -0000      8.162
+++ engine.c    10 Apr 2008 23:21:40 -0000
@@ -719,6 +719,9 @@
                }
                break;
          default:      /* don't send a reply */
+               smi_log(SMI_LOG_ERR,
+                       "%s: milter returned bogus status %d in state %d\n",
+                       ctx->ctx_smfi->xxfi_name, r, ctx->ctx_state);
                break;
        }
        return ret;
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