I have certainly had issues with my various 44-40's. I have stoned burrs from the firing pin hole and the "step" on the recoil shield to make the cylinder rotate properly. I have also had to modify my sizing die to set the shoulder back a little farther in order to get the rounds to seat deeply enough in the chambers. My Uberti rifles also have rather tight chambers, limiting the combination of bullet size and brand of cases. With smokeless powder, I've had to deal with bullets tending to telescope into the cases. It all makes me wonder why that is still my favorite cartridge, but I do like it. When all is working, anyway...
CC Griff