have you checked the wear on your pins? Reason I ask is that when discussing with Marcus, the owner of RC Shox, he mentioned that the pins can rotate. So, if say you have a pin that is worn, I am wondering that maybe the actual diff action can change if the pin is worn enough causing one minute for things to feel great, next, too be tighter than you desire.

Now, this may not apply to your issue, but throwing that out there for someone in the know to better respond, especially since you have been using your setup for a few months.