>...What happens to TDS when the DI resin becomes fully exhausted?
It is not easily quantificable, but in almost all cases, the resin will "let go" of some of the junks that it absorbed, then started to work a little by absorbing some ions back. The net affect is almost zero, but if you are not lucky, you may end up with worse water than you started with.
I usually recharge/change the resin if the conducitivity is more than 0.33 uS (If I remember correctly.)