Ok, I took everything apart and cleaned it all very thoroughly. I also chucked the expander in a drill and polished it with scotch brite and the od is within tolerance. I ran a case through the die without the expander and it came out with the tolerance (id, od and neck wall thickness). After doing all of this I put everything back together and gave it another try, and wouldn't you know everything is working fine now. It is difficult getting the right amount of case lube on each case without getting too much though. Thanks to everyone who gave suggestions and advise. I really appreciate your help.
You should try One Shot - again a lot of bad rep for improper use. With One Shot - you can't over do it, but you HAVE to shake it very well, you HAVE to apply generously, you HAVE to wait for at least 1 minute.