I have more words in my head than I should be saying for these things, hate them with my life right now!
Passenger side replaced under warranty, now the driver side is acting up out of warranty. I pulled them both off to re-grease the crap out of them and do a quick inspection. My driver side hub had the back C-clip pop out of it, causing my front end to lock up while driving down the road feeling like I am in 4Hi. Fixed the c-clip, re-greased, MUCH better down the road now but still get the odd lock up while driving down the road, mainly after a right hand turn but not always (5 rights leaving my block, no issue, one right turn on the straight to work and it locks, POS). Now focusing on other front end components tonight, rotating tires tonight due to the wear from the hubs locking, hopefully I can find something else wrong but if it all checks out then I do a have a plan...
Buy a new set of hubs, put them in the toolbox in the truck. Take the old hubs out, smash all the locking hub crap out of it and install back on to keep dust/dirt out of the hub. When I need 4wheel I will have to allow myself 10-15 minutes of cold removal and install the new hubs sitting in the tool box. Once I am done I will take them out so I don't deal with the same crap in 2 years.
Spoke with Warn, no hubs available, no plans for R&D.
Not looking to do a $2000 hub conversion, can't think of any other hub companies that make them for the 6.4 but if you know of one please let me know! I'll gladly be the test bunny