The 1356 T case is tough, them breaking on a stock vehicle is rare (if they ever even break), I never read of failures... the only time I broke one took some serious abuse and it was no fault of the transfer case, when the rear axle pushes hard enough forward to puncture the radiator and bend a leaf spring turns out you break the snap ring groove for the output shaft bearing and put some aluminum in the chain which can make the shifters bind and keep it in 4x4...
Open axles should have no affect on the transfer case binding. The transfer case locks the front axle to the rear axle when in 4WD. When turning a corner in 4WD the front and rear axles rotate at different speeds which causes the binding. Driving straight helps the binding to relax which helps to eliminate the thunk. It does not guarantee no thunk but it helps a lot depending on how long the straight drive is.
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