Scott,
Nasty gear!  From the pictures it looks like you got a rough cut gear without the finish grind. Too much metal. You can compare the profile of the bad gear to a good gear by using three pins (similar to thread gauging) and a micrometer.

The bad news is that I don't think your investigation is over. How does the mating gear look? Is it worn as well? Was the bad gear hardened? At a minimum you should inspect the replacement gear at 25, 50 and 100 hours.

If you send me the bad gear and a good gear I can compare their profiles and hardness in our metrology lab.

Until you are sure of the cause of the problem you don't know if the pin is still in the hand grenade.

Regards
Brent