Rob, sounds like your problem is that the plastic spacers are not going all the way into the end of the bodies. This is something i have seen, and is a problem i have on the shocks on my own car. The method i use is as you mention, in that i put all of the parts in and seat them individually - fully pressing them home with an allen driver. I actually think that this dimension either varies, or is different to how it used to be. I'm fairly sure that my old non threaded set didn't suffer the same problem.
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