I just finished a call to SanDisk on a 64GB USB 3.0 Extreme drive about my USB won’t fit in my computers. The technician said she had never heard of this issue and yet I find a recent posting here.
I first tried to plug the USB drive into my OLD desktop that has been around for years and it was tight. The device went in about 1/8th of an inch. Understanding I have a new USB, I pushed a bit harder and Windows Explorer came up with the folder available. The USB did NOT fully go in all the way. I would say it went in about 3/8 inch.
Furthermore, I took the same USB drive and plugged it into my laptop, 9 months old, and same issue. I had to push far enough to get the drive to be recognized by the OS. Finally the folder came up for me to transfer data.
When removing the USB from my laptop, the internal USB plug came out with the USB drive. WTF! I now have to send my laptop in for repair.
Taking my digital calipers out, setting to millimeters then imperial, I measured and compared to another USB drive that fits perfectly. One of the dimensions was off. Measuring the inside blue corners. The good drive measured 2.07mm / .0810in on each corner. The SanDisk, left side 2.23mm / .0885in and right side 2.56mm / .01000in. Looking with a magnifying glass on the right inside I can see an excessive amount of blue material further in the plug that I could not measure. So obviously, this drive is too tight.
Very much something to worry about if you don’t want to pull the inside plug out of your laptop. 
