LR edit adjustments didn't transfer correctly after image come back from photoshop

I am not sure why you reset the image which you sent to Photoshop. To leave the LR adjustments in place would have produced a TIF image which included these adjustments (and, optimally derived from Raw) that your client liked.

It is true that these adjustments would no longer be themselves adjustable further - not in the same nondestructive way, using LR, referring to Raw, as they still are within your master LR image (the one that hasn't been to PS).

Resetting LR adjustments merely means returning them to LR default processing - it does not mean any sort of zeroed, or neutral processing as would be the case with an imported bitmap. The cumulative effect of burning that default presentation into pixels, leaving aside that it may not be technically optimal for the content of your particular image, and then applying the same set of adjustments, will not necessarily produce the same result. LR minimises the difference between a Raw and a TIFF where it can but some details - the profiles available, how WB or Exposure etc even operates for these two cases, editing headroom - cannot be made identical. 

(incidentally one reason your cloning spots may have failed to line up, would be if you had cropped the image somewhere along the way. That needs to be burnt into what goes to PS, or done in PS, or LR cropping needs to be deferred until the image returns from PS, or else LR cloning needs to be done from scratch onto the returned image from PS.)

It sounds as if you still want to retain the LR adjustments live and alterable, even for a version of the image which has gone to Photoshop. Perhaps the Edit as.. Smart Object method might have met this requirement better? With this workflow the editability of the LR settings moves into ACR embedded within PS, but those are effectively still the same global and local LR settings nonetheless.

RP

No you can't apply edits on raw files directly to rendered files. They are incompatible due to the nature of raw data and rendered images being completely different. You should do all edits on the raw file and then send that to Photoshop to do your last edits.