I have a sammi with 4:1 t-case gears and a locker in the rear.  Is it even reasonable to think I can run the stock axles and gears with 33's for any considerable amount of time with out breaking shit left and right? Also if I get PS, would it be better to use the locker in the front so there is less wear when driving in 2wd. My thought was to put it in the front, as I am worried it will wear out the rear end from driving around town,  it already seems to bind, click, bang and pop a lot in town as it is. Plus I do not want to have the rear end break on the trail and not be able to get home, if the front goes out I still have 2wd.  Any thought would be helpful.

I am planning on doing a locker in the front soon too, but my friend has the same t-case gears u have and a locker in front for over 7 years. he drives it on road some too, and he hasnt had a single problem.  he did within the last couple years get beefy axle shafts, not because he broke something, just because he wanted too.. 

I would recommend doing the same ASAP, just because sammy shafts are small.

I ran the same setup for over two years now and when the 4 to 1's  broke in two I went to 6.4 to 1's with 33's and 3.73 gears, have broken the welds on my frame arm (the drivers side)that holds the t case in twice,the second time I welded the arm on the inside where there was no weld and I use a stock rubber mount on that arm and let the t case hit the bottom of the body to keep it from ripping appart again, it just bumps the sheetmetal under the drivers seat every now and then on a hard hill climb, I have over 12 thousand off road miles on it and have not broken an axel as of yet but did start to twist the splines in the back after a year or so with the 16 valve, if you take the locker out of the back and put it in the front only your asking for trouble, if it bothers you just take it out, I have rears up front and ramp a 944 on a 20 deg. it gets around great and will make a better driver out of you, get gears and two lockers down the road and your good to go, I'm putting in 4.30's locked and yj's from trail tough. p.s. your going to need a good clutch befor you go over any big rocks.

For the Transfer Case mount, I run the bullet proof mounts and welded a piece of angle iron to the inside of the long bar to keep it from twisting.

As for the 33's, it depends on your driving habbits.  I have twisted the splines with a front locker on mine, but I haven't broken an axel or a Birfield yet.  Since then I've upgraded to the Calmini axels and an ARB without any problems.

As for wear with your front tires when in 2WD mode, just unlock the hubs.  That way your front end is free spooling and doesn't turn the locker when driving around.  It should act the same as it does now.

1) Put the locker in the rear FIRST. They have 80% or better of the traction going over tough obsticles. You're better off with 2wd with posi than you are with 4wd.

2) With 33's you'll be on the BLEEDING EDGE of reliability. 31" is really as big as you can go "safely". As always it depends on how you drive, and the type of wheeling you're doing. You "Can" wheel with 33"s but... you'll more than likely break something at some point - even if you're careful.

3) 33" is a bit big for 4:1. You should really look into 4.6:1 at MINIMUM - prolly 5:1 would be better. The extra $150 is WELL worth it. Go with Petroworks if you're going with front locker, as it COMES with the 2wd low shift kit 

4) You can do a welded diff in the front - it's the cheapest way to go, and if you have the Petroworks 2wd low option - you'll have the best / cheapest setup.

I thought he already had the locker in the rear. 

I thought he already had the locker in the rear. 

Oh - whoops - yeah - keep it in the rear. I don't think the rear can go in front anyway.

It sort of can.  If you change over to the heavy duty Calmini axels your front and rear spline will be the same.

It sort of can.  If you change over to the heavy duty Calmini axels your front and rear spline will be the same.

  it depends on which locker he has! none of mine have the side gears that came with them, the ones I have are the cheaper better ones that use the stock side gears, he needs to take his appart and fix it, could just be springs or the shims need to be ground down a little if the lockers are not cracked, when the lockers do break they break locked most of the time so you will make it home ok.