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Good thinking locksmith E11. Also sometimes if you change it for a different mechanism the roller or mushroom keeps need to be brought out a touch by chiselling a small amount out of the plastic.

To test this make sure all your keeps are aligned at right height and push the door in from the inside as you lift the handle, if this works then you will have to bring your roller keeps out, hope that makes sense.

If me I would remove all the keeps and then replace 1 at a time and each time closing the door to check. This way you will systematically find the problem keep. I re aligned each keep when I first fitted the new mechanism but I did not try locking the door whilst adjusting them.

I will take off all keeps and start again I think, checking to see if it locks after each keep is fitted. Thanks everyone, if anyone can think of anything else to try that reminds me of a KVF I had to replace last year. The replacement went in fine, but was slightly different.

When the handle was pushed down, one roller would engage a 'keep', and the other would become free. When it was lifted, the other would engage, and the first one would become free! I had to move a 'keep' up in the end, but I've always wondered why the replacement was so different in that respect!

I have found a lot of manufactures change locking mechanisms slightly by moving a hook or roller by a few mm, seems like there's no reason other than to make our lives more difficult locksmith E11, the Yale g2000 is a prime example think there's 4 different hook and roller combinations.

 I was called out a few weeks ago to a difficult to lock patio door, lock was ok worked fine when open but when shut.  after filing keeps, adjusting keeps, adjusted hinges then it got easier kept adjusting hinges until they would not go anymore but it locked fine but doors were well out of line checked the frame it was twisted and out of level what chance have you got this bloke said it’s been like this for three years since he moved in it was a new build.

I can now clarify, because I've had exactly the same situation occur today with a KFV. It was a failed 'key-winder' that was a complete pig to get open, as the deadbolt wouldn't retract no matter what I did (I've designed a new tool to help with this in future.
 
The situation I mentioned above, arises when a KFV Key-winder is changed over to a 'Lever/lever' KFV mechanism, with results in the rollers being put into the 'keeps' when they should be free from them. So for those that haven't come across this before, just be aware, as you can get locked in, or out.

Anyway, the 'cure' is to simply mark a line on the door frame where the rollers would be in the 'unlocked' position, and then turn the roller keeps up the other way, and adjust slightly.

After all of the problems and you very kind people giving me suggestions, it was the new mechanism (or so I thought) that was the problem. After spending near on 2 full days on this (yes time is money) Well locksmith E11 I decided to buy a new mechanism and fit it just to try narrowing things down more. Low and behold, it bloody well worked fine.

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