I think that Kris is right. Perhaps you forgot to install the key in one side or the other. Hopefully you did not ruin the new coupler half or the shaft itself.
Take it apart again. Clean up the shaft with emery paper (Plumber's Cloth). Use Blue Lok-Tite on the threads of the set screws. Make sure that you leave around 50 thou space between one coupler half and the spider. If the spider was damaged in any way, replace it now and save yourself the aggravation of having to do this all over again. The space is needed to allow for expansion as the parts warm up.
Let us know what you found when you dismantled it.
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Today's Featured Article - Oil Bath Air Filters - by Chris Pratt. Some of us grew up thinking that an air filter was a paper thing that allowed air to pass while trapping dirt particles of a particles of a certain size. What a surprise to open up your first old tractor's air filter case and find a can that appears to be filled with the scrap metal swept from around a machine shop metal lathe. To top that off, you have a cup with oil in it ("why would you want to lubricate your carburetor?"). On closer examination (and some reading in a AC D-14 service manual), I found out that this is a pretty ingenious method of cleaning the air in the tractor's intake tract.
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