Hi,
There shouldn't be any stress at all (or very very minimal at least) driving with hubs locked in 2wd. It does sound like a strange one.
Is it a totally standard front dif? No locker or anything?
How has the hub failed? Sheared the splines/bearing collapsed?
How are the CV joints, could they be binding at all?
It does sound like a delayed reaction to the initial failure, which is entirely possible, but check everything carefully when the second hub is replaced.
I'm certainly not aware of any regular problems with TLC freewheeling hubs.
Good luck
Sam
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