[JeepersShaggy]

So my tires have been a little wore since I bought my ZJ, and the belt in one of them snapped... So, I needed to replace one, and the stock size I bought for it looked a little funny. This makes me sound like a vehicle idiot, but I had never really looked at what size tires were on it before, not even when checking air pressure, etc. The rest or the tires were 235/70R15s, with the stock 225/70R15. So I went a got another, as it was all I could afford at the time...

Long story short, I put the stock size tires on the front, and the slightly larger tires on the rear, and drove to work... So it went great for a little while, then started to wobble as though I had gotten a flat or something in the rear. Check ties, nothing. Problem persists, so I limped it home. Smelled awful like sulfur, came from the rear end. Removed carrier, bearings spin incrementally like the second hand on a clock. Replaced both carrier bearings, reinstalled and refilled with fluid.

Test drive again. No problem to be found within a 20 mile drive... So I drive it to work the next day. When I get there, the smell of sulfur is back, and right before getting there the rear passenger side feels like it's sluggish. Tow home, remove carrier and shafts, inspect. Bearing bad, replaced it and seal, put back together, replaced fluid.

Test drive again in several very short trips. No problems found, but too worried to take it any distance for fear of trashing something again. So I thought I'd check with the people with the answers. I'm more an engine and suspension guy, not great with the driveline.

Could this be coincidence the wearing of bearings in the rear end?
Could the different size tires front and rear be causing the Tcase to try overpowering the rear end and burning parts up?

What is the extent of the damage I could be causing to my ZJ?
Oh yeah, 95 ZJ 5.2 V8, All time 4WD.

Thank you to anyone who read through all of that and still wants to help!

[jeep95xj]

Very bad move. With full time 4x4 you NEED every tire to be the same size. That goes for every truck with 4x4. Any time you use the 4x4 the front tires spin just a hair faster than the rears. With a smaller tire that tire will spin a hair faster than it should. Good way to break u-jounts, axles, t-case, and who knows what else. Buy the right tire for the truck. If all your tires are low on tread replace them all. A brand new tire even of the same size tire is going to be larger than an older tire with mileage on it. Be safe do it right. If you dont the cost in the long run will be a whole lot more than 4 tires.