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It isn't that that causes the binding. The binding is caused by the flex in the plate that the lever goes through. It's a tolerance seal, so just a hair of deflection causes binding. That's why it does it worse with a new o-ring, because you have more pressure pushing back against it in the...
The small bridge that retains the fuel lever under the shutoff cover; you tightened the screws just a hair too much. That's why the idle won't come back down consistently. Pull the shutoff cover off and back one of the screws off just a hair and see if the lever frees up. Moving it by hand now I...
If you've tried all that and you still have a leak, it's safe to say that you have a hairline crack in the hydraulic head there, most likely in the threaded area. I've run across this a few times. Only leaks going down the road because the pressure and vibration is higher and faster.