Ye very odd they are all 180x180.... Only think I have noticed is the file size is quite small could it be the resolution?
I found this tutorial: [GUIDE] How to create facepacks (cut-out and normal) - The Dugout Football Manager Community
Did you do like described in the guide? I've never done it so I wouldn't know.
Not sure. I tried creating it all over from scratch, without using "save for web" and just saving it as a standard PNG. Can't see any difference, but you're welcome to give it a shot: