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Rebound 'D' Shaped Rod

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I have a 97 CR250.  I just rebuilt the front forks with new seal and bushings.  Afterwards the rebound adjuster on one fork would just spin.  It would never bottom out.

 

I took it apart and both ends of the D shaped rod look mangled.  So I ordered a new one.

 

Questions:

 

1)  Why is it mangled?  What did I do wrong?

2)  What does the upper end of the rod engage with?  How do I get to it?

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It was probably forced or hammered in last time serviced

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It was probably forced or hammered in last time serviced

Unfortunately I can't blame it on the last guy since I just rebuilt them myself.  It was my fault.

 

I was able to reshape the rod into the D shape.  So I installed it and everything works good. 

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