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Dave-
Thanks for the detailed write-up. I am in a similar situation. Bought '06 AWD with 160k, noticed seepage at transfer case. Checked it every month or so for the last year, but evidently let it run long. Started hearing a noise above 45 mph that changes tone based on whether accelerating or decelerating. Pulled the drain plug and NO fluid came out. Contemplating a transfer case swap this weekend. Your comment about ATF T-IV has me confused. The fill plug on my transfer case specifies 80W90 gear oil. What is the ATF for?
 
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