Don't know. Maybe you guys both need the opposite side switches. That would be convenient haha. What side did you need?
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No, I have never had any problems with the transfer case. Only time its opened up is when I remove the drain and fill plugs.
As for the undercarriage, its a combination of both. Those pics are from the weekend after I went to Mammoth which has salt/sand on the roads for snow. There is some...
Mileage is hard to say, very hilly here and I don't let the gauge drop below 1/4 before filling back up. With that said, I estimate it to be around 15 combined highway/street.