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I had the exact same problem with mine 2 weeks ago. Radiator Barn? I used a small file all the way around the fitting on the radiator for about 15 minutes and it went right on. Frustrating isn't it when new direct replacement parts don't fit.
I did not get any leaks. I still had to really force it on. Rubber gromets? You mean inside the trans line fitting? File a little at a time and keep trying it.
I don't remember any rubber gromets. It should look like a Ford style fuel line disconnect. The pipe coming off the radiator should have a bubble flair around it and the fitting on the lower trans cooler line should have four prongs that clip on over the flair when secure.