you know... I don't know wether or not I was agreeing. I believe only partly, haha.
Since the front output is fed by the chain, which is connected to the input via the VC, I don't see how the front can spin faster than the rear. Now, if it can, then yes, I agree that it will destroy the VC.
But the rear output is "more connected" than the front output.
As with a differential, power will take the path of least resistance when it can. Remove the VC from the equation, and the truck won't move at all; it'll just spin the front output shaft. The VC serves to limit the amount of freedom the front output has by linking it to the rear output. It's a really clever design IMHO... But I digress...
The rear output is not a direct-drive on the AWD case. The input drives the planetary gears, which in turn drives the sun gear (connected to the front output) and the ring gear (connected to the rear output). In the 44-05 Auto-4wd cases, the front output drives the rear output directly, and the clutch coil 'grabs' that shaft as necessary, linking the front and rear outputs. They function completely different... THe bottom line is that removing the front shaft in an AWD case can and does allow the VC to turn. **Not freely**, but turn none the less. The VC is what limits that movement.
Here's an experiment to try: With the front shaft out, mark the output flanges. Get in the truck, start it up, put it in gear, and brake torque the engine for, say, 15 seconds. Do not let the rear wheels spin, just put pressure on the driveline. If the VC is working properly (i.e. not siezed) the two outputs will no longer be lined-up.
Then again... I do now remember that when I had my front shaft out, truck in gear, but blocked by 2x4's, the front output was still spinning. So I could definately see power braking, or very quick acceleration, destroy the VC.
Exactly as I described. Were it not for the VC, it would allow the front output to freewheel... just like one rear wheel of a 2wd truck spinning on ice.
Under normal, conservative driving, I do not believe it would cause too much harm.
It's your t-case,,, do as you see fit. But Ford obviously didn't want it to see sustained slippage... That's why they clearly state not to run a different sized spare on the AWD case, even in a pinch.
But, for all I know, those few thousand miles without a front shaft in my truck, caused my VC to go bad, which is causing this PITA vibrations I've had for well over a year.
Although the AWD traction is still there, and it doesn't seem like my VC has frozen/seized, due to still being able to get the rear tires to spin without the front spinning (first very icey day of winter a few weeks back).
That's where I'd put my money... VC's are a funny beast... I'd love to get my hands on one and see what makes it tick!