Alright
@nakman, you wanted analytical.
But what does that tell us? I have no idea how much is acceptable. Obviously the differential is there to allow for tire size and speed mismatch, so you can turn and all that.
So I'd assume what you're worried about is heat from asking the differential to have a constant mismatch. When you go straight with perfect tires the two sides are turning at the same speed so the differential isn't differential'ing.
But when there is a mismatch the spider is slowly turning, building heat. I'd think mechanically that shouldn't be a problem as long as it's not excessive and you have enough lube in good shape. It's doing this all the time anyway, as you drift left and right, the road curves, normal air pressure differences, etc.
With an auto locker or limited slip excessive differences might be a more significant problem, that might be wearing couplers, friction packs, pins.
I couldn't find anything Toyota that says this but it's a commonly specified thing for commercial trucks. They variously seem to fall in the 1.5% mismatch as a maximum. If that is applied here then using a brand new slightly more than 16/32" should be matched with nothing more worn than 8/32".
My suspicion is that across a regular axle, no LSD or auto locker, that is conservative. OTOH if you have a LSD that is probably not a bad rule of thumb.
It's even harder to find recommendations for front-to-back when you have a transfer case. I found some references in 4WD tractors that suggest you want 0% mismatch up to a 5% forward bias (e.g. the front axle pulling rather than the rear axle pushing). That might be more about control than wear, I dunno. Then again I've always understood that new tires go on the back, not the front. So control again, e.g. under steer, not over rather than an axle wear issue?
From Axle Tech's AMT-0445 Failure Analysis document.
From Dana/Spicer Application Guide DAAG-0080.
From Meritor's Technical Bulletin TP-9441.
