The air cap on the Eclipse serves a few purposes. he first is to aid in aligning the nozzle. The front, inner cone is shaped to fit the outer contour of the nozzle. The second function is to seal the nozzle against the inner contour of the brush body at the nozzle base. The cap adds pressure to the cone, forcing into the brush body to complete a surface seal. The holes around the circumference at the front then guide air out over the nozzle. The least important part of the assembly would be the O-ring around the threads at the bottom of the assembly. Virtually all the action takes place in front of that.
Now, if you overtighten the air cap, it is possible to compress the nozzle, thus distorting it. It will no longer be able to create the seal it needs to, and you will experience air entering the paint stream as bubbles in your cup.
If you have scratched the conical shaped taper inthe brush body, where the nozzle sits, you will not get a seal, and air will enter the paint stream.
I would suggest using the air cap off the new brush, along with a new nozzle to test the old brush.