Is there a special way to dial the button in?

Can the catch be TOO tight is what I'm getting at? Meaning, if it's too darn tight will it cause failures to feed. Seems unlikely, but help a brother out.

I don't see how having the catch too tight would create any feeding issues. The only issue I could foresee would be problems ejecting the mag once it was empty. You would have to depress the eject button extra deep to eject the mag (assuming the catch was threaded too tight).

The only way to loosen it would be to remove the bolt catch lever.... And that pin is a PITA!

To loosen the mag catch? No need to remove the bolt catch lever. You just need the eraser side of a pencil to depress the mag release button extra deep and then the mag catch lever should clear just barely enough to unthread it out one turn.

I've never been that lucky to be able to depress it enough to not have to remove the catch! Luckily, one time the bolt catch had a screw in pin. Other time.. Fuuuuuck.

I can do all this.

BTW this is on the custom lower, so I can't just look at my 5.56 lowers and say "ah yes". I'm familiar with threading the thing in with it super depressed and all.

Don't sweat it, makes no difference.

This is just a thought. My guess would be its more the magazine than the catch.
If the magazine fit sloppy. Maybe...just maybe the mag catch would push the
magazine out of alignment enabling it to feed a cartridge properly.
Once again just a thought.