I have replaced the front/right bearing a total of 2 times.... mixed in with re-tightening the wheel bearing nut probably 4-5 in total.  I am not sure why its just the passenger but this is the side that broke an axle shaft past the birfield joint long ago.  I ended up replacing everything (but the knuckle) since the piece of axle rattled around and scored things up. After that i also completely rebuilt both sides (seals, bearings, felts).

I never see any evidence the double star locks have moved. I correctly torque the nut each time also.  Is there anything else I should be looking at as a contributor?  Im at the point where I am about to swap the entire axle assembly 

Other than the break, the only change(before bearing failures) left is that axle shaft. And did the axle shaft breaking cause deformation of the axle housing?

Is that side bent- axle housing or axle shaft or both?

All I got.

Tighten up and torque it again, and mark any and all nuts and bolts with slippage mark paint. Any paint really. Are you positive you seated the bearing races completely? SineCred makes a good point, the bearing housing could be distorted.

Other than the break, the only change(before bearing failures) left is that axle shaft. And did the axle shaft breaking cause deformation of the axle housing?

Is that side bent- axle housing or axle shaft or both?

All I got.

Yeah possibly... it seems something is wearing the bearing is my best guess.  I have a full front setup... just have to swap 3rds and OTT steering.  Probably rebuild the seals in that... ugh... money money.

I have replaced the front/right bearing a total of 2 times.... mixed in with re-tightening the wheel bearing nut probably 4-5 in total.  I am not sure why its just the passenger but this is the side that broke an axle shaft past the birfield joint long ago.  I ended up replacing everything (but the knuckle) since the piece of axle rattled around and scored things up. After that i also completely rebuilt both sides (seals, bearings, felts).

I never see any evidence the double star locks have moved. I correctly torque the nut each time also.  Is there anything else I should be looking at as a contributor?  Im at the point where I am about to swap the entire axle assembly 

What are you torqing each nut to?  What procedure are you using to seat the wheel bearings?