Check you sizing die. Put the ram all the way up (handle fully down). The die should be screwed all the way to the shell plate. Then back it off not more than 1/4 turn. I back off even less. I only leave about .002" of clearance. I use my barrel to check the rounds. I don't reload .40, but, I do reload 9 mm, .38 Special, .357 Mag, and .45. I have not had a problem with Dillon dies not sizing correctly in those calibers.
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