I have set up used gears multiple times with good results. I put used rear gears in my front axle many years ago, with no issues (which was the only time I moved gears from one carrier to another). I swapped a stock gov-lock carrier for an e-locker in my rear axle at least 5 years ago and it's all fine. I also replaced the pinion bearings last year on the non-serviceable Getrag rear diff in my Cadillac and so far it's been perfect. In each case I was able to get a good pattern using normal setup methods.
It does seem like we have a trend going here where nothing seems to give a good pattern and new gears fix it (there's another thread in the last few months). I can only assume there was weird wear/damage or the gears were super high mileage.