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I'm working on a 40K Terminator squad currently and I'm a little perturbed about how soft the plastic is. It's so soft I can barely work with it. Has anyone seen this before?

Im not sure how much experience you have with plastic but its not supposed to be hard/brittle like resin. However, if its soft and flexible like the green toy army men than somethings wrong. It should be harder than that.

GW's older(2006 and older) plastic formula was much softer than the current one in use. It was also a lighter grey. Perhaps that is what you are using and aren't used to it.

However it should only feel soft to your razor blade, not to things like finger nails.

The dark or light coloring is irrelevant, that's just a matter of how much coloring was mixed into the batch. Raw polystyrene is translucent and the parts are colored in greys or tans (as GW used to do) because it makes it easier for your eyes to pick out details. When I worked in plastics we mostly used polyethylene (think milk jugs and soda bottles) There's a thousand types of plastic resin to choose from. My guess would be kits made in different areas used resin from different suppliers.
If your parts are REALLY soft, there may have been contamination and you got some solvent or oil in the plastic batch. I'd make them exchange those

I got a bad mix once where the plastic was near-transparent and it was very brittle. See if you can find another model from the same era and manufacturer and test it.

Either somehow the plastic got heated up while you were working on it or its poorly made. The GW plastic should be fairly solid.

I demand pics! I must see these rubber Terminators.

I'm suspicious GW does have at least 2 different mixes of polystyrene, used for different sprues - their terrain kits (e.g. the new WHFB round tower) are a noticeably harder plastic than normal figures. This difference seems to be consistent, not just random manufacturing fluctuations.