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This is a 90% efficiency furnace, correct?
If you want, we can do a phone call. Flame rollout is primarily caused by a bad heat exchanger. Many times the problem cannot be seen without actually opening up the area where the heat exchanger is and examining it. Many of the heat exchangers used small stamped "rings" holding the two halfs together and if one or more of these has popped out, this would cause a flame rollout situation.
You need to actually watch the ignition process and also during a heating cycle to see what the flame is doing. It shoot straight into the chamber without going to one side or the other.
Could also be over fired. Gas pressure set too high.
If you remove the filter does it trip?