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Did you make sure the lower control arm was clocked enough when you slid the torsion bar into it? If its too relaxed or close to normal ride angle when you insert the bar, it will never have enough adjustment to tighten up when the adjuster bolt is sent in.
I think if the bars were one flat off in the hex (LCA not down far enough) you would never get it off the rubber bumper with all the adjustment. Bars have probably been switched from side to side and just fatigued out. Or maybe LCA bushing shot as suggested above.
Also look at the sleeve in the K-frame. Welds might be toast etc. And of course possibly new bars are in your future. Nothing mechanical lasts forever.