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Turned out was the handle .... It was a very subtle difference but it was different ... now sorted 
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In reply to Post #4
i have 6 of this particular model (5000 GTE-C) - I compared the handles/spindles and they are the same .... I didnt think to compare the screws (obvious when think about it  ) .... will check them out tomorrow, thanks
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In reply to Post #3
Will be something like this 
Compare all three screws, see if one is slightly shorter, try that in all three reels until you find one that allows the handle to fold correctly.
Are all the reels the same model, as there may be some variation in handle screws.
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In reply to Post #1
Certainly sounds strange, once folded I guess you can't fit the screw to the spindle?
My best guess is you either the wrong handle or screw for the reel possibly both.
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In reply to Post #1
Sounds like a phone call to the helpful chaps at the Tackle box: 01322 292400 to me 
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I have multiple sets of baitrunners (rear drag) and all handles fold when unscrewing the screw from the handle/spindle, but the screw stays in place/connected and can slightly tighten again so no risk of losing it.
I have one reel that to get the handle to fold, the handle screw needs completely disconnecting from the handle spindle. This means needing to keep safe the handle and handle screw seperately.
Assuming any of the above makes some sense, has anyone else had the problem and did you resolve it?
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Tackle