Damn, sounds like a quality control issue that needs to be resolved with them. I wonder how bad the internal solder joints are on them too if the wiring is slipping past their QA and making it out the door.
As far as your transfer case whine, it makes sense. Partial throttle where the load on the gears is less than a coast or at throttle (in my head I refer to it as "neutral throttle") can make the gear mesh be barely in contact in the case. Mine makes a metallic growling noise above 30 MPH in 4 Hi when I'm at tha tneutral throttle point. If I give it a little gas or pop the clutch in and coast, it goes away completely. It was overall reduced a little bit by switching to AMSOIL. Their Manual Transmission Fluid is good for both GL4 and GL5 applications so I can use it in both my H55F and the tcase, which is good because my tcase slowly leaks into the tranny. This is after using both Royal Purple and Redline.
I suspect I'd been hearing that same gear mesh from the front diff too, but I haven't put it in 4 Hi since finally changing its fluid out for the AMSOIL Severe Gear that i run in the rear diff. Probably won't until the snow flies again next winter