Thank goodness found the problem.  For some reason the saved character had a mis-applied morph.  It was one of Trekkiegrrl's M4 younger morphs, cheeks softer.  When originally applied it applied in a strange way.  The dial at 1 applied it at a strength as if the dial was dialed to 6.  To apply it as if it were 1 the dial had to be at -4.

 

After re-loading it was acting like a normal dial.  1 meant 1.  So at -4 it was radically "un-applied".  That's why the chin was pulled up and in towards the neck.