Nevertheless, I call it bad engineering, no matter what manufacturer.
Bad engineering how? Something written in a manual ages ago, as a precaution/recommendation (which was likely just to boost tire sales at the dealer), with no supporting failed differentials in decades since is hardly bad engineering.
Certainly there have been millions of combinations of the things Subaru warned against and yet there’s no evidence anywhere that this has caused failures, makes your position more ludicrous than the LSPI boogeyman. Lots of hype, not much objective evidence it’s as destructive as claimed.
And yes, I’ll use other, lesser AWD vehicles as examples that the caution only truly applies if you have different size ODs (26” vs 28” ex.); tire size that started with same overall height, worn from driving or misalignment are never going to damage the differential systems.
But it does exactly that, compensate by locking the diffs. Too long of a lock and it burns up, especially when only partially locked.
Sounds like redbone just doesn't understand how these systems actually work. As stated, a different tire diameter is causing the system to believe either that one tire, or the other three tires (depending on if the tire diamter is smaller, or larger than the others) is slipping. So of course the system is going to try and correct that, that is the entire point.
I can't think of any vehicle on the road today that doesn't at least have a brake activation traction control system to stop a slipping wheel and send power to the other wheel that does have grip. This has been a regular system on vehicles now for at least 15 years. Even on a 2wd vehicle with an open diff if you run different tire sizes side to side on the same axle without deactivating the traction control, you're going to have driveability issues.