This has nothing to do with the problems the OP is having.
Never use a direct box on the speaker output of a class D or bridged amp without verifying with the manufacturer that it's ok. In the case of the Subway amps (and every other amp using this output module) it's NOT ok and could damage either the amp or the device the balanced output is connected to.
Direct boxes provide a balanced mic level signal from an instrument or line level signal. There are a few exceptions that can take a speaker level signal but never from a BTL (bridged) source like the Subway's speaker output.
See my above post. The do make them for connection to the output of tube amps which are never bridged and always isolated.
Quite possibly.
On the Subway amps, the tuner out is a buffered in phase output of the input, its ideal to split the bass signal pre everything.
When using 2 amps, always verify proper polarity, many amps (and intermediate outputs) do not guarantee polarity is not inverted (as you suggested)
To the OP: have you verified that there is no damage to your 610? A bad driver will cause these symptoms, as will one driver wired out of phase.
With 2 x 4 ohm cabinets, be sure your amp is set to 2 ohm mode.