8.25 carrier wear

It's been abused, a few 2nd and 3rd gear one wheel burnouts over the last few years.

That right there is the culprit. No one ever thinks about just how fast ONE SIDE spins during a burnout. They are not designed for that type speed. That's what causes them to over heat, cook the gear oil and start galling the small pinion gears to the cross shaft. I agree 100% with Garrett. No way would I use anything out of that housing. I'd start all over fresh with everything, right down to the bearings and races.