How does your /etc/hostname.carp1 look like?
passwords masked (it's the same unique password on both nodes):
fw1:
inet 10.24.5.1 255.255.255.0 10.24.5.255 vhid 55 carpdev vio1 pass <pass>
fw2:
inet 10.24.5.1 255.255.255.0 10.24.5.255 vhid 55 carpdev vio1 pass <pass> advskew 128
I was wondering if the configuration of vio1 could be the case at boot because I compared it with other interfaces and it's different as I am adding the routing for VPN to CARP IP.

/etc/hostname.vio1:
inet 10.24.5.3 255.255.255.0 10.24.5.255
!route add -net 10.8.0.0/16 10.24.5.1

I would be better doing this in /etc/hostname.carp1 as 10.24.5.1 is not available yet.

And YES!
After incorporating routing into carp1 device configuration fw2 booted with ARP entry for carp1.
I need to test it a little more but that could solve the case.
I don't know how it was working in 5.8.
Aghh... such a mistake :(

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