Okay, Navy Lifer - I will check those splits to be sure they are in the fore position of the bar. However, I do know the lubricant is ONLY b/w the bar and the inside of the rubber bushing - none of which touches the exterior of the bushing or the metal c-clamp brace or frame, unless it leaked by the split and found it's way b/w the bushing and the frame. However, I should note that prior to this recent "fix" there wasn't any notable lubricant to begin with. Also, to make the point of the lacking lubricant on the initial install, even the passenger side rubber bushing was working it's way out of the clamp, but in a uniform fashion thereby resembling enough friction b/w the bar and the bushing.
When the driver's bushing was flopping out, I do remember the split of the bushing to be in the aft position, so I am assuming they did the same this time around also - so I will check.
The way things are "working" it seems the lateral shift of the bar is wedging the rubber out of the clamp - so the question IMHO is what could cause the bar to move laterally in a more perminent fashion; there is a physical shift a good 3/4" of the bar to the passenger side and the only thing keeping the bar from going further is the bend in the bar meeting the driver's side metal bushing clamp.
I did not replace the bar in the suspension rebuild - ??? bent bar??? - incorrect install of endlinks??? I don't know.