I recently purchased a Lee Classic 4 hole press with die sets for .38, .45, and 9mm.
I loaded 500 .38 Special and when I used the fourth station with the carbide factory crimp die, all worked well. There were a very few cases where I could feel the die resizing the round a little bit. Most of them did not seem to need resizing. This squares with what Lee states in their instruction sheet. They say not to expect the post sizer die to touch every case.
Then I went on to loading .45 ACP. In every case, no matter what the head stamp, the post sizing die passed over the loaded round with very noticeable resistance. This is on both the upstroke and the downstroke. Has anyone else had this happen with the Lee factory crimp die in the fourth station? I adjusted the die twice per the instructions, with no improvement. Any idea of what is happening?

It depends on what bullet you are using.

What bullet did you use on the 38 special?. If it is lead and has a crimp groove the die should provide a roll crimp and should firmly be in the groove. On the 38 all it really does is act as a crimp die.

On the 45 was it lead or FMJ? The 45 is big and fat so I am guessing it just has more to grab and it is providing a taper crimp which goes down the case which is what you are feeling.

On the FCD, you raised the ram until the shell holder touched the base of the die, then turned the big lock nut. Then backed out the adjustment knob. Now put a loaded round and raise the ram and screw the adjustment knob down until it stops. Back out the round and turn the knob 1/3 to 3/4 turn. Now raise the ram and the bullet should be taper crimped.

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Still Running Against the Wind

Check that you are not over expanding the mouth of the case on the 45. The Lee FCD has a carbide sizer and if you over expand the mouth of the case, the mouth of the case will drag on the carbide sizing ring.

The die is acting exactly as it should.

I use 200 gr lead SWC bullets and when I use that die, which I must in my tight chambered bullseye gun, there is a distinct resistance when the cartridge goes in and comes out.

The only time I get little or no resistance is when I use R-P brass which is slightly thinner that other major brands,

+1 on what Jerry said.
Remington-in and out smooth. Winchester-drag in and out. Mixed GI (1961/71) occasional drags both ways.

Jerry described exactly what I am experiencing. The bullet is Missouri Bullet 200 gr SWC Bullseye #1. I had not thought about the difference between the roll crimp on the .38 and the taper crimp on the .45. I guess the die is doing what is supposed to do. Thanks to all for their responses.

I would also suggest backing out your feed through expander die maybe half a turn. Sounds like you are just belling the mouth a little too large. I started out with a Lee Turret press and have since moved up to a Lyman Tmag II. I just didn't like the amount of play in the turret on the up stroke, now don't get me wrong the Lee press works and is a great press to start with when on a budget, but I'd rather have consistency on each and every stroke. On a side note If your using the Auto Disk measure they don't really like fine ball powders like 231 or 296, the powder will leak out of every crevice. I prefer to use the Lee Perfect measure, cheapest on the market and I have found it to be more consistent than my RCBS and Lyman.

If reloading lead bullets, the die will meet more resistance due to the larger diameter bullet (such as in .45s, .451 Jacketed vs .452 lead), so that's common.

I have the Pro Auto Disk and do not get any leakage with HP-38. Along with adjusting the flare, adjusting the die in or out centers the disk drop hole over the drop hole in the base. I found this out after having leakage on some calibers and not on others.