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How hard are you having to press to install these switches on the PCB? I imagine if the PCB is pressing on the switch housing hard enough to deform it and interfere with the keystroke, then it must be absurdly difficult to install in the first place.
Any pictures you can share? Can you maybe install a switch without the top housing to observe what’s happening inside?
Much harder than I had to with the Cherry switches. I've been experimenting with applying pressure outside of the PCB and cannot replicate the issue. It's only when the switches are inserted.
However, after some experimentation last night, I did realize this is indeed an individual switch issue. The problem is that they work perfectly fine until they're fully inserted into the PCB. Then they got choked. I've identified a couple of problematic switches and re-assembled them but the issue is still there.
I'll try and remember to share some media later. I like your idea of installing without the top housing. I'll try that later. Thanks for commenting.
Quick personal note on the U4T’s, after about a year, I’ve had multiple fail on me, they’ll require multiple taps to work. I’m going to look for a new tactile switch soon.