We were having a problem also. But, we found out that the nursing staff was not FIRST depressing the rod until it releases from the syringe. They were pulling the rod off of the syringe instead of depressing -- and then the plunger does not screw correctly into the syringe barrel. Have you checked that? It was user error for us.
We had the sales rep do an inservice and I have not had any problems since.
Bobbi