I understand the idea of unloading the front CV/Axle system with a switch and unlocked hubs.

1: How about this as an application model --
Install the unlockable hubs and leave them locked, just like stock.

I don't install the hubs because they stick out too far with the wheels I have & are subject to trail damage. Mainly carry in the event OEM hub splines shear. Just pop off existing OEM hub & replace with Asian manual lock.

2:Break a CV joint/axle and unlock the hubs to get home with 2WD? Swordy, did you do this once?

Yes, When my CV joint failed I used my TOD disconnect switch but if CV joint has failed chances are it is not rotating & no torque applied to wheel. Got home in 2WD. If necessary just take off front OEM HUBs (Metric Allen) to keep wheels from rotating torque back thru driveshaft

3:Maybe the TOD would go nuts and the TOD disable would still be smart, so as to stop things rotating. I am getting lost in too many layers of disconnect.

TOD disconnect stops relay from energizing but see 2: above

Swordy, jump in anytime to if you have anything to add or to correct me if your of another opinion.

Bob