The original poster never mentioned the gun / guns that the ammo was intended to be used in. A bolt gun may get away with cases that a gas gun will not. Starting to size at 90%? That will never fly in a .308 AR, and likely not in an M1A even if it has a GI barrel.
JJ is correct, spray the heck out of the brass using Dillon, or similar case lube. It needs more lube than .223 ever thought of needing, the brass needs a good coat of lube. You may even need to size your brass a bit shorter than what the case guage says it good for reliable function. I took .005" off the bottom of the full length sizing die. Small base dies made no difference.
A stuck case remover set is needed, you cannot remove the expander from a die that is stuck. The sizing die reduces the neck diameter smaller than is needed, then expander opens it up a couple thousandths of an inch, on the down stroke of the press handle.