Ok.. Here is the scope.. Finally got my KJ back from chrysler. So I am going to need new summer tires. I held off ordering my BFG's waiting to see what the damage would be on my KJ. So I am heading home for holidays in a few weeks and my old man has an F150 with 245s. So me and my brother is going to do a test swape to see about rubbing issues, etc. My question is....
If I go with 245's and I got a flat, would there be any major issues with driving several hundred klicks on a 235 tire?

I would not recommend it. Driving with a different size tire places a tremendous strain on your transfer case. Just think about it, three wheels are spinning at one speed and the oddball is trying to spin faster to keep up.

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'03 Liberty Renegade
119,000 miles
K&N Drop-in
Factory Skids
Towing Package
245-70-16 BFG All Terrains

How are you going to test fit the 245s from an F150 on a KJ?

Well I have some black steelies, so I'll just pop the tire of the F-150 rim and put it on the the black steelie. Not going to drive with it, Just wants to see how much clearence there is and if some minor trimming is required.. I think there will be.

This should not be the case with open diffs, no? Might put a bit more strain on a limited slip.

You turn a corner, the outside wheel is going faster than the inside wheel, happens all the time.

I wouldn't think it would be a problem short-term, although you may want to keep it out of the 4x4 modes.

Of course, you could buy 5 and rotate the spare.

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Black '05 KJ Sport