Devo 12s throttle and aileron moving together

I have been using Deviation FW for a couple of years, with no issue. Recently, when trying to fly at the local field, I had selected airplane configuration on my Devo12s, loaded with v4.0.1, and Channel 3 (throttle) tracks properly.
Aileron (Channel 2)tracks from -75 to 86 with throttle input, and an additional range of +43 to -36 with right stick horizontal movement.

Have setup new models, loaded latest nightly and re-flashed 12s with the same result, gone back to stock FW and even checked the internals for signs of damage.

I am completely lost, and would be eternally grateful for any insight into troubleshooting that I may pursue.

Help me Deviation, you are my only hope.....

Maybe check which stick mode it's in ...And give Heli mode a try to see if it behaves the same..

Try calibrating in deviation again?

I have tried all 4 modes, Heli-Plane-Multirotor.

I also re-calibrated the sticks.

The TX.ini file reads:

current_model=1
language=0
music_shutdown=0
mode=1
brightness=5
contrast=5
volume=10
vibration=0
power_alarm=0
batt_alarm=4000
batt_critical=3500
batt_warning_interval=30
splash_delay=35
time_format=0
date_format=0
[calibrate1]
max=2654
min=1496
zero=2195
[calibrate2]
max=3643
min=373
zero=2013
[calibrate3]
max=3728
min=478
zero=2117
[calibrate4]
max=3905
min=543
zero=2235
[calibrate5]
max=2169
min=2166
zero=2167
[calibrate6]
max=1030
min=1024
zero=1027
[calibrate7]
max=657
min=653
zero=655
[calibrate8]
max=460
min=454
zero=457
[calibrate9]
max=800
min=796
zero=799
[calibrate10]
max=2070
min=2065
zero=2068
[touch]
xscale=-264548
yscale=163840
xoffset=1013
yoffset=-25
[autodimmer]
timer=20000
dimvalue=0
[countdowntimersettings]
prealerttime=30000
prealertinterval=10000
timeupinterval=10000
[telemetry]
temp=celcius
length=meters

Is the mixer messed up?

Post the model file that's doing this (.ini).

I re-flashed to the latest nightly - still not working
Calibrated the sticks - still not working
Changed Mode, Model, Aircraft - still not working
Cleared any mixes - still not working
Changed Telemetry type (from DEVO default) - works 100%
Changed back to DEVO - works 100%

I am suspicious that all the flashing FWs may have produced a ghost in the machine...

Thanks to everyone who helped debug, this forum is a welcome change from many of the mainstream RC ones with the countless trolls.