Master Locksmith W12 Key Cutting Mortice Rim Cylinder Repair

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I think locksmith W12 have hit the nail on the head. I've had this where 7mm spindles have been fitted instead of 8mm. You wouldn't think it'd make that much difference, but that extra movement eats away at the follower over time.
 
I'd say definitely a mechanism problem rather than mis-alignment. If it's behaving that way with the door open or closed, it's suffering from wear somewhere in the mech. You've tried the usual thing of removing the keeps one at a time

So that pretty much rules out alignment probably as does trying it with the door open, of course, check the keeps are aligned vertically as well, just to be sure.

Mechanisms on Wood doors will go out of alignment quicker (I find) than those fitted to UPVc, and all that swelling and shrinking with the hot and cold will cause the mechanism to generally wear quicker.
 
I did one similar yesterday. A Fullex that was difficult to lift the handles high enough, so I removed the 'keeps' to see which one was causing the problem. Instinct told me it was the top one, as that had wear marks. Turned out to be the middle one though, just needed moving a fraction downwards.

Just curious, have to tried it with the lock out and used a camturner instead? I'm assuming it'll act the same, but one Fullex I came across a while back, was fussy over the profile of the cam. Seems mad, I know, but I tried three different brands, before I found one that worked consistently.

Had one similar to this, replaced a gearbox because the door would not lock at all and the new one was doing just the same as yours. Locksmith W12 adjusted all the keeps that was the initial problem that had knackered the first gearbox.

Ended up a combination of handles and keeps. The handles were ever so slightly out of line so when the mechanism resisted on the keeps it would not always throw all the way. Funnily enough it worked ok on one side and not the other and not a split spindle. If you threw it quickly or held it in place it worked.

I opened the hole up and allowed the handles to line up properly and it worked perfectly. Have you changed the gearbox? The drives at the back of the gearbox have a habit of breaking off, there are 2 for when it is in split spindle operation and sometimes part of it can break off and stop the gearbox throwing all the way.

You can see them through a slot in the gearbox, give them a really close inspection. As all ERA mechanisms they are trouble, however if it’s the 45mm backset with the 2 x small hook cases which are abundant in composite doors (usually with the shaped strip) it is almost definitely the mechanism, I recently did 6 in the same week, 2 in one property.

Nasty, horrible pieces of crap, not unheard of to fail same day as installation. Also locksmith W12 try and refrain from just changing the gearbox, you will more than likely find you will be going back later to change the lot.

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