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The purpose for adjusting for AOE is so that the first tooth of the sector gear meshes with, and only with, the first tooth on the piston.
SO, if the first tooth of the sector gear touches or drags the second tooth on the piston and/or the second tooth of the sector gear on the third tooth on the piston before the first tooth mates with the first tooth on the piston, pull out the dremel.
Hectic, I think your piston is releasing early and the wear is from dragging along the last tooth on the sector gear. You're lucky you don't have more metal teeth on the piston or you may have pouched your sector gear. Check your AOE again and ensure the sector gear is not engaging the second tooth on the piston.
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