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As long as you get exactly the same tire as the others the difference between a new tire and one worn 50% isn't going to cause a problem. The difference in diameter is less that the difference between a underinflated tire and a correctly inflated one.
If you can't get the same tire then you should replace them.
What your stressing when the diameters are off is the VCU not the transfer case, either the rear or the center depending on where the different sized tires are.
Steve
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