Problem solved! All the drama was caused by a flat battery on the new NVRAM. It only reads 0.4V instead of 3V
This is why the serial number didn't transfer from the BCU to the new NVRAM. After removing the battery with a soldering iron and replacing it with a similar 3V Battery from a Fax FCU the heartache is over.
Thanks to everyone who tried to help. Great Forum!
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