I would,
try another bolt
remove barrel, inspect and measure the diameter and depth versus your other upper
if all looks well re-install and try again.. maybe a different barrel nut? Tighter/looser torque of said nut..?
Lastly, try another barrel on the problem upper if possible before you write it off. Within the narrow range of tolerances I find you can sometimes get two parts that are less than ideal in fit.
My bet is on the barrel not sitting deep enough in the pocket, and perhaps the bolt is setting up TIGHT against the barrel lugs when sprung forward into battery, making it very hard to manually open. You can check this by getting a candle or felt tip marker and blacking up the bolt lugs, once re-installed and operated you can see where the contact points are.
It will give you an idea anyway... Maybe the upper pocket is not true, and is a wee bit crooked.
just thoughts for you to chew on...
good luck
EDIT:
Curious.. how are you clamping your upper to be able to remove barrel nuts and such? Are you using a jig.. if so what type? Some jigs I have seen were better than other for these jobs. I purchased the Brownell Barrel Extension Torque Tool and never looked back. Mucher cheaper than the Geissele Reaction Rod
youtube.com/watch?v=n4Y_JrfDcXU