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USP40 intermittently not cocking after firing

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I've done a bunch of searching around the forums and haven't found anything regarding this problem.

I have a USP40 that I often shoot with a 9mm barrel installed. I mainly shoot steal plate challenges with it. It's a1994 (KE) that I have installed a match trigger kit in. I also updated the hammer strut and control latch when I installed the match trigger kit.
Everything worked fine for aprox 2000 rounds. Now suddenly the hammer intermittently doesn't remain cocked after firing. About 50% of the time, after firing a shot, the hammer will be down and the pistol will be in a double action mode.
Dry firing the pistol and manually cocking the pistol does not replicate the problem. Cocking the hammer manually acts normal. Pushing on the hammer after cocking does not make it fall. I have every indication that the sear engagement is solid once the hammer is cocked.

Any thoughts?

Thanks in advance for any thoughts or ideas.

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