I didn't mean assemble the sear incorrectly, I meant install the SHB into the frame incorrectly.
I just went and compared some .40 & .45 SHB's, and a couple of 45/40c pistols.
The SHB's that allow for installation of the thumb safety assembly have a different (shorter) length & dimension of the R/F SHB rail (and corresponding frame groove). This is required because of the way the thumb safety moves and functions on the right side, requiring more space in the frame behind the trigger bar.
They also have a raised portion on the L/F rail, which is part of the design that holds the different style of ejector. The older ejector on the older SHB simply rested against the left side of the SHB, between the frame and the SHB. The new style also uses a headed sear pin to help hold the ejector, versus the flat pin in the older style.
The older SHB's that won't accept the thumb safety have a taller, thicker rail at that R/F spot (and correspondingly more plastic in the frame, without room for a thumb safety behind the trigger bar).
FWIW, my '08 production 45, with the thumb safety, allows for a small amount of up/down shifting at the very front of the SHB. It's been that way since the beginning (as has at least one other M&P 45 with thumb safety I've checked). It will also allow for a slight 'rising' of the left side thumb safety when the trigger is fully pulled. It functions and fires normally, and probably has more than 5K rounds fired through it by this point.
My 40c ('10 production), which wasn't made to accept the thumb safety option, has the other style SHB with the taller R/F SHB rail and frame groove. No movement in the frame. This gun has seen a little fewer rounds fired, and also functions and fired normally.
Both of my guns have the older less distinct 'softer' reset, although my 40c does have what I suppose might be called a 'transitional' slide stop assembly. It has the added lower R/R corner angled inward on the right side, was was done prior to the newest 'enhanced' design with the thicker welded sides, so the right side can add even more pressure against the trigger bar to aid in leftward movement back under the sear nose. It has a less distinct click before actual reset, but a noticeable click at the actual reset point. (More so than my older 45.)
None of this helps you, though, except maybe to suggest that whatever is happening with your 40c, it may not be involved with the movement of the SHB & L/S thumb safety, nor may those things even be a "symptom" of what's going on with your trigger/sear reset. Dunno. Not there to look at the gun.
If it's a problem with the trigger bar loop (meaning the angle, especially if the angle or 'gap' has been 'adjusted' at some point), which isn't letting it reset under the new sear nose 'teardrop' (versus the original sear with the D-shaped nose which resets over the trigger bar loop), and/or something else, it needs to be diagnosed and corrected.