After years of using a single powder measure on my 550, I finally decided to purchase a quick change kit. My 550 was an older 450, that was converted over. I had been using the old style powder measure without issue, so I never upgraded to the failsafe system.

Obviously with the new quick change, I had to finally upgrade. I got everything installed, put the new powder measure on, and it doesn't fully return. I've done everything possible, adjusted the fail safe rod, and even when I'm pressing on the powder bar, it will not fully return.

Here is my old powder measure, notice, the bar is fully closed.

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The New one, the bar will not fully retract and sticks out 3/32".
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This will let powder into the bar, and it likely will work (I haven't had time to do any testing yet), but clearly this is very different from the old bar. When I take the fail safe system off, the bar returns fully without problem, so there are no burrs hanging it up, it is 100% the fail safe system.

Is this normal for a failsafe powder measure, or do I need to call Dillon and arrange for a replacement?

I will read more but want to mention something right off.  In the first photo, you are missing a part.

There is a small white plastic bushing (nylon?) the interfaces between the powder bar operating arm (black) and the powder bar itself (silver).  It is a small square with around hole in the middle.  It completely fills that square notch in the powder bar.  It appears to be installed on your newer measure but is too small to fill the notch.

I suspect the little plastic goody installed on the newer measure belongs on the older measure.  Try moving it to the old measure.  See if it fits.  If it fits, leave it on the old measure.

Order a properly sized replacement part for the new measure.  The properly fitted piece will more completely actuate the powder bar.

I could be completely wrong, as I do not keep up on the model variations.

The powder in the first picture is old, it may have been a manual measure at one point and converted, I’m not sure. Anyway, part of the kit to convert my press included the newer failsafe linkage, unfortunately the measure is so old, it needs several other parts, and even then, I’d have to drill a hole for the linkage screw. So I will probably leave that one as it. With the older measure, as shown, it does not have the nylon bushing at all, just the metal arm.

is this tight enough?

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Yeah, I tightened it down according to Dillons Video, enough to hold a business card, but its still about 3/32" of an inch away from fully closing. From the picture posted above, his isn't fully closed either, so I believe it's normal, I will email Dillon tomorrow to double check.

Unfortunately it looks like my old measure cannot be upgraded to the Failsafe system without buying multiple additional parts and modifying the measure itself, so I will probably just continue using it as I have, not that it has ever caused me any problems.

Paying attention and looking with your Mark I eyeballs carefully still works as good as ever.

Oh, I'm not concerned with powder drop failure, I have a mirror I mount to check each loading at the bullet seating phase. I'm concerned with having a consistent drop, if the powder measure doesn't open all the way and my drops are all over the place, it makes it pointless to have a progressive press.

Hmmm.....

just took a look at mine  ( 3 different PM’s)
550
550
650

all three have been running fine for several years

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That's is exactly what I was looking for! Thank you.

My older measure goes all the way to the left, so I was just hoping this new one was buggered.

yeah...I think you’re good-to-go

looking at mine the range of motion is limited here...

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It's a poor photo, but the nylon square actually fills the entire slot. The powder measure you're seeing is brand new, and the powder bar in that photo, is brand new and came with it.

I just did this two weeks ago.

Had the same issue ,can't really tell you how I got mine working just kept messing with it.

Now the only issue that's bugging me now is I have to run kinda slow ,or I get little powder debris all over the press.

Not an issue on my older power measure ,but I only have used it for .45apc.

Would adding springs to the new measure help?

This does not make sense.  Use your eyes.  That square does NOT fit the slide.

Like I said, it’s a poor picture, it makes the bar look like it’s a part of the measure. I have the measure in front of me, and know if a square fits in a slot.

Two more pictures from different angles for you.
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The Dillon sliding type have never been known for all that much accuracy.
The only other place you see them is shotgun loading and a lot of people quickly buy a better micrometer bar instead of the bushing system.

Die cast metal does not compare to cast iron rotors on polished steel.