Crash,
My Denali XL with AWD (not 4WD) had the same issue starting around 30K. GM wouldn't replace the front differential or the intermediate PTU as they said it was within "GM sound limits". Got worse, but leveled off around 50K. Drove me crazy between 55-65mph. Was worse when lubricants were warm. Had all synthetics installed and it was better for a short time. Might have just been new ****. Traded on Brick in Jan 2010 at almost 90K and never had a failure.
Just one of those things that will drive you CRAZEEEE!
Hope your's is different and easily fixable. Know you work for Ford, so you may get better treatment, but if they look at your ECM.... watch out....