More Problems After Suspension Rebuild

It may be those two piece bushings are too thick for the application (regardless of what the seller lists. :( )
I can't say this is or is not the direct cause, but possibly a contributor. Also..
Multi-piece bushing assembly have a metal sleeve and the ones for fine threaded strut rods have retaining washers like shown in the shop manual.
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When torqued to spec, the retainers contact the metal sleeve.
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40 ft-lbs for all car lines.
And yes there should be a roll pin or cotter pin as an extra safety measure.