What carrier do you have in there, stock/aftermarket? Did the axle & axle bearings spin freely when you took the axle out? Just wondering if the axle bearings are bad & got the carrier hot enough to melt the PC inside the carrier housing?
Lonestar twin row, which was all new with only 5 hours ride time on it. No color on the axle or bearing races indicating it got hot, and they all still spin freely, and axle came right out by hand.