[DesertRatTom]

There is a slight bit of slack because of the way the raising/lowering rod attaches to the router. But it's very slight. Is the lock lever all the way loose or partially tightened? The raising and lowering parts are pretty simple, not much to catch on.

 

[DesertRatTom]

Mine is quite smooth, so I'm not sure what to tell you from here. Clean off the plunge columns. Check down the one the spring is in to see if something is caught in there. Is it interfering with using it, or is it just a small annoyance? If you move the base up and down many times, does the catch remain the same or reduce slightly. If it reduces, then it's some substance on the columns or the guides the columns pass through.

Beyond that, I have no idea, mine is very smooth, although there is a little friction so the thing doesn't just flop down. I'm not that mechanical that I know the answer.

 

[DesertRatTom]

Forgot, in the meantime , I’m going to get a few things put together to sell so I can order one from Home Depot.
This one was the display at the store so who knows.

That's where I got mine. The package arrived with no tears or dents or crushed corners, is always brand new, and returns are easy. Display models always show some signs of abuse after awhile. Bargains often turn out not to be.