Just a few suggestions on what could be happening here:
- After my 5-lug swap and larger wheels/tires my passenger side tire rubbed the fender lip pretty bad while my driver's side didn't, not even a scratch
- My driver's side quad shock rubs the main shock while the passenger's side does not (even though both quad shocks are reversed)
- Check the actual amount of play in the axle with either callipers or a dial indicator. The "feels like" method can vary widely.
- Is it possible the car could have been wrecked and maybe taken a hit in the axle, maybe bending the control arms, etc. ?
- Is it possible the quarter panel could have been replaced at some point and not be in factory specs ?
- Check your torque boxes and make sure they are not torn
I'm thinking if you are sure you used the correct length axles and did the C clip install correctly that it might be a perception thing. In a perfect world everything would be symetrical, but maybe it's not a prefect world. Of course you would probably already know about the C-clip if it wasn't right... If in doubt you could always take it to an alignment shop and see what they say.