Well, I have no idea. Obviously it isnt normal. I suggest you follow the advice you were given in the other thread, as I have little experience with Max to ZB work.
It sounds like your tool has become corrupted for some reason or another, somewhere a long the line. This can sometimes happen for any number of reasons…problematic geometry, overlapping UVs, stray vertices…sometimes people push their system too far beyond the point where it can keep Zbrush stable, and errors occur (saving a tool after getting an “out of memory” error is usually a recipe for disaster.) I would think it might be a case of not importing the new mesh/UVs correctly, except you say it happens when importing a just exported base level mesh as well, which makes me think your tool is corrupted.
Here is the procedure for importing new UVs though, FWIW:
http://www.pixologic.com/docs/index.php/Working_With_Uvs
As explained in the other thread, you could subdive the base mesh with the new UVs up to the necessary level, and attempt to use mesh projection to capture the sculpted detail. You could also attempt to “repair” your current tool, by deleting all subdivision under the highest level, and using “Reconstruct subdivision” to try and rebuild the lower levels.
Like I said, Im only guessing, I’m sorry. I have no idea why your tool is acting like that. Out of curiosity, does it still “explode” if you disable UVs in the texture palette before reimporting?