I am having a very similar issue. I cannot add players to my active roster even though I only have 6 players and 4 Jim Unknowns. When I try the message says "The active roster is full."
I am willing to do more testing or give more info if I can. Just ask and I will provide what ever testing you want me to do.
Edit: I did try to delete everything in the save game file mentioned above and got no improvement.
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