[Al Skierkiewicz]

That is very odd. Ours is so tight we have a hard time pushing the breakers in. There isn't a chance that the cover has shifted a little and you are inserting the breakers between the cover and the outside of the female terminal is there?
And I know this sounds strange but I have to ask. Have you asked if anyone has made any adjustments to the PD? I have had more than one team stretch open contacts because they thought they were too tight. One was on cable terminals for the Spikes, one was on the old fuse block and one was the main battery connector. The last one produced the most damage.