Graygoose still a bit confused as to you stating that I should set gains before running auto tune, but here's an update.
Received the replacement amp yesterday and ran the auto tune per the manual/kicker youtube videos. Gains zero, pink noise, HU volume 3/4 (31). I did all my dips (including HPF) prior to the tune also even tho it doesn't specifically state to do so in the manual.
After the auto tune, I ran different kinds of music to set the gains. NOTE: I did try the pink noise to set the gains, but doing this never got the amp limited out. The problem would then be if I set the gains with pink noise which is almost to max, when I switch to music my gains were way off and also limiting out immediately. So I set the gains to various songs I like to hear.
Results are in and this thing is pretty good. My gains are set about a little more than 1/2 way. I purposely tried to limit it out and I barely heard any distortion at that mark. As compared to the defective amp where gains were limiting early and where gain settings from one channel effected gains for the other.
Do these speakers ask for more power than what the kicker key provides, definitely! But I must say that now I have the replacement amp and it's running as it should, I am much happier with the overall volume and gain settings than I was prior. Again it's not perfect and maybe one day in the near future I'll dive into the full dsp install, but for now it's very very good. Side note, I moved the amp location from under the center console area to the upper glove box. This made tuning etc much easier to access.
Now the only thing left I have to improve a bit is my sub situation. I have a p2d4 10" amplified with a sound ordinance m350. It was originally in a cheap attend box, but I purchased a netaudio tall passenger side box (12" now with an adapter for my 10") from a fellow member (thanks for the quick shipping!!!). I put the sub in this box and tho is sounds sligthy better(deeper, more rounded) it just doesn't sound right. I'm not sure if it's the amp (gains are maxed out, not good?) or if it's the sub (not enough/too much enclosed volume?) or if it's a combination of both. I know the netaudio box (tall passenger 12" box with 1 cu ft) are well regarded so Im excluding this as the issue.
Thanks again for everyone's help.