So you are saying you lost 40dB on one in/out trip through your patchbays? That's not supposed to happen!
20dB is sort of an odd number, because you'd expect to lose about 14 with a mismatch between +4 and -10. You can lose 6dB by running the wrong kind of cable, like an unbalanced cable between gear that is expecting balanced.
So conceivably you could have a +4 to -10 mismatch and also be running the wrong kind of cable. That could potentially add up to a loss of 20dB.
I see a potential balanced/unbalanced issue going on, with both the patchbay and the cables. Also, the gear on both sides of the patchbay has to be basically set to the same levels, i.e. are you running +4 balanced gear or -10 unbalanced? Or, your patchbays could be weirdly screwed up, although it would be odd to have several of them show the same problem.
I'm really guessing here, because I've never had an experience where I lost that kind of level going through a patchbay. You might want to try and hardwire some of the gear together, just to see if the level problems are indeed caused by the patchbay. Or swap in a different patchbay and see if the units you are using now are the cause. Good old "process of elimination" troubleshooting.
Are your
PB40's new or used? I have a stack of Furman PB-48's that I am gradually retiring because they don't seem to be holding up well to even light use, and they don't hold the jacks tight. I'm liking DBX PB48's better, although *any* patchbay of this kind of design is a little suspect and pretty lightweight in the bigger scheme of things.