"10.1.0.0/16"
Really – why??? For what possible reason could you have to use a /16 on a lan segment?? That is a summary route type of mask, not a something you would put on actual network.
Well AFAIK there is no performance impact or any other negative unless you actually put 65k devices (read: many devices) on such a subnet. We have way more than 254 devices, so a class C subnet is not going to work. I guess /20 would have been better, but it makes the IP address ranges harder to read and I wanted the new IT person to be able to quickly understand the network without having to figure out netmasks. Not an excuse, but since we only have about 700 or so devices I do not see an issue?
"LAN2 GW?"
Why would lan2 have a gateway?? If it has a gateway its not a lan interface but a wan interface.. Do you mean you created a gateway in pfsense? Or you actually put gateway on lan2 interface?
Perhaps we have different reference points, hence our terminology does not align. LAN2 GW referred to the point of view of a device attached to the LAN subnet. It would see the LAN2 interface (IP) on the pfSense as its gateway for its subnet. The LAN2 interface in pfSense does not have an upstream gateway as it is a LAN interface as you correctly mentioned.
If you do in fact have downstream router then pfsense should be connected to such a router with a transit network, or you run into asynchronous routing issue when devices from lan between pfsense and your downstream and devices in the downstream network talk to each other.
I think this might be the issue. Unfortunately I do not (yet) know the internals of what is behind LAN2 (Sonicwall firewall in my case, in your picture - the 192.168.1/24 network is unknown to me), I just know that LAN2 of my FW is attached to a Sonicwall firewall that has behind it some network 10.5.1.0/24.
I fixed this by adding a static route - seems like the ping responses were a fluke and it did not work reliably as per your explanation. A static route from 10.1.0.0/16 to 10.5.1.0/24 via LAN2 was the key.
Thanks for your assistance.