The one roster rule quirk I ran into similar to this was in/after Spring Training in an online league a few weeks ago.
I had players in my MiLB system who were on MLB contracts but not on the 40-man because they had previously been DFA'd and cleared Waivers so were just in AAA. When Spring Training started, I did what I always do and called up the full 60 players by bringing up first high-end prospects then anyone who might be able to fight for the roster bubble, which included some of those previously-DFA'd players. Once Spring Training ended though and I wanted to pare down to my 25-man, I couldn't demote any of those 'MLB-contract' guys without DFAing/Waiving them again.
My guess is that's an OOTP problem and not a rule MLB rule because OOTP doesn't differentiate between ST roster invitees and the Active Roster, so to the game it looked like they had been called up despite not having been put back on the 40-man.
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