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reman'd box as well?
i just went through this on my chevy pickup. took 3 reman'd boxes before i got one that wasnt shit. one of them, it was much harder to turn left than right, which is one of your symptoms.
the cutoff isnt what really causes an issue. the issue is that the reflectors are designed to have the filament in a very specific position. if the LEDs are not in the correct spot, that will cause the headlight to throw light incorrectly.
only way to know if your combo works is to test it
my buddy with a 2016 wrx put LEDs in his, and they look fine. but he spent $150 on his LEDs.
as you said, some housings work fine with some bulbs. other housings scatter and dazzle everyone, and then die after 10 hours. only real way to know is to use a combo that someone has already used, or...
personally i'd swap the D35 for a 29 spline 8.25 or a D44, and put the locker in that. I absolutely would not want an autolocker in the front of a vehicle that was going to see DD duty in the snow.
Anybody have any experience with any of the ebay pocket fender flares? I'm sure the Napier flares are better, but $500 for some plastic isn't in the budget right now.
If you couldn't see any movement then it is probably ok. However, since you can get them on ebay for $25-30, I'd highly recommend you replace it anyway. With your 4.5" lift I assume you have bigger tires as well. The spacer is a pretty common failure point, and only takes a few minutes to swap out.