Quote, "2. a problem with the transfer case due to the fact I have run 2 new tyres on the rear of the vehicle while 'using up' the life of 2 older tyres on the front of the vehicle. The suspension expert says this is a 'no no' as the wheels/tyres are a different diameter and will destroy the transfer case! And suggested the tyre people should have advised of this when fitting."
WJ/G & WH & WK all run Quadratrac II, Quadradrive or Quadradrive II. When driving around town, they are in 4HI.
Quadratrac II sends power to the rear wheels until it detects the front and rear wheels turning at different speeds. It then transfers power in a 50/50 split to the front and rear.
Quadradrive or Quadradrive II do the same except they can also send power to the non spinning wheel side to side, almost akin to diff locks.
The problem you are going to encounter running wheels/tyres with a differing diameter is the transfer case will start acting erratically as it detects the front and rear spinning at differering rates. It can also cause the axles to have a dummy spit if they are different diameters side to side.
With the Wranglers, Cherokee's and ZJ/G Grand Cherokee they have 2HI, 4HI, 4LO etc and do not have to worry about the tyres being the same diameter front to back as they have to manually select when to engage 4WD, with the above mentioned models it is permanently in 4WD.
With these models it is advisable to rotate all 5 tyres to keep them as close to the same diameter as possible.
I rotate mine every 5000km, (it's getting done tomorrow by coincidence).
It's your car, but I pesonally would get the tyres matched all round including the spare.