NyLock nuts are meant to be used for only one use and not reused.
Regarding the pedal, the smaller washer was certainly not the correct size to begin with and since it was dented, the nut was over tightened.
My suggestion is to turn/twist the pedal as you tighten the nut and then stop, when the tension begins to show, that friction has started to prevent the pedal from moving smoothly. I have about 3 threads exposed past the end of the nylon insert.
For the past 6 years, I clean and re-lube my pedal shafts yearly following the above tightening method. I have never had a "new nut" come loose as you have experienced.
The same caution about not to reuse old Nylock nuts applies to the Mirage Drive chain and cable nuts too. Always buy new nuts, to have on have for any service.
_________________ Dr.SteelheadCatcher Warrenton, OR
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