I've pulled the relays again, all 4 speaker relays and power relay. This time I was more aggressive cleaning them. I was able to remove some oxidation on the contacts applying some pressure and using paper. Also I deox'd the **** out of the speaker selector switches. You can get some internal access via the underside of them. Also deoxit was used on the rear mode & impedance switches.
Reset the bias down to 2mv after warmed up. Was a little high from my last setting, about 4.7mv warmed up. I noticed the amp was getting warm and fan was turning on. I definitely need to change these bias pots, they are the worst pos I've dealt with. I would imagine vibration could be enough to knock them off setting, 25 turn pots would solve this. Also, when the amp got warm, I would here a humming sound coming from the amp itself, not the speakers. Not sure what that means (the cooling fan was on at the time and the amp was bridged). Bias was a little high and I've since lowered it. But at the time, if I shut the amp down or let it cool for a min or two that humming sound would stop. Not sure if it was coming from the transformer or what. The fan runs quiet and is not from the fan running.
I haven't tested in btl mode yet, but so far the issues I was having seem to be eliminated. I think the problems I was having were from dirty switches and relay problems.