Hopefully modders will begin to fix these issues soon. If it's the same menu for sending settlers to settlements (I think it is), then you need proper encounter zone and location for the cell the workshop sits in, and the workshop must be configured for said encounter zone. If its the same menu for sending settlers to settlements (I think it is), then you need proper encounter zone and location for the cell the workshop sits in, and the workshop must be configured for said encounter zone. That way, you can swap companions even if the settlement has reached it's limit. You can still dismiss a companion to the last settlement they where recruited from, as long as you cancel out of the menu rather than choosing a spot. On another note, I discovered that you can somewhat circumvent the issue of companion swapping. Seems like an oversight on Bethesda's part.

Yet he's still held to the settlement limit for whatever reason. They don't even contribute to the settlement, other than Codsworth, but he's never counted as a citizen. I just wish that companions wouldn't go towards the settlement limit so that you could put them all in one spot. You could put them in the truck stop nearby, not ideal but its a small walk, I am guessing when modders get hold of this game they'll extend the truckstops build range closer to sanctuary, seems logical to create one big build zone. Is there any way of getting rid of settlers without resorting to killing them? Although it's strange, I have 12 inhabitants but only 1 point in Charisma, which should add up to 11 max.

Interesting, so I assume this applies to companions as well. You can't have anything more than that regardless how many beds or how much happiness you have. The limit per settlement is 10 + your charisma stat.

Fallout 4 send companion to settlement