That perhaps you mixed up the 4 butterflies between shafts and/or they are installed incorrectly.
One other possible solution was that when you freed them up from being frozen they were eaten away enough to cause gaps and improper sealing, If thats the case you will be needing new butterflies, and in todays market an expensive proposition.
SO lets look at the proper placement. Even though they look identical you actually have two sets of differing butterflies, one set (the primaries) have a beveled edge on one half of the butterflies making this edge thinner that the rest, where as the secondaries are not beveled at all and have a squared off edge completely around the entire circumference, so they are the same size edge all the way around. (although in some I have seen just a slight bevel of the edge)
The primaries are situated on the shaft so that when they open the buterflies have that beveled edge face up into the oncoming air/fuel mixture.
I always loosely install all 4 screws for both butterflies and the entire shaft I am working with, then close the shaft so the butterflies seat. I use a small tapered pin punch to center any off-center butterflies, then slowly, evenly tighten all 4 screws. I test and retest to make sure the shaft opens easily and closes and realigns itself to completley close the butterflies.
If you are still having problems, take out all of the butterflies and make sure your shafts can open and close properly, maybe something is preventing that main shaft from closing all of the way.
Good Luck,
Bill White
White Automotive
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HAVE A NICE DAY!!!!