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I have a 97 exp. bought brand new. After 150,xxx miles where the drive shaft connects to the transmission ( i guess this is the transfer case) a bearing come out, causing severe vibration between 45-65 mph. The vibration from the drive shaft broke the housing on the tail stock. My transmission folks "fixed" it and 6 months later it broke again. They covered labor.....
Upon their recommendation I sent my drive shaft to make sure it was "true"....it was
Well....I got 226,xxx miles now and the vibration come back in between 45-65 last week. I took it to another repair man who I trust dearly and they said I needed a new transfer case.
I don't know a whole lot about transfer cases but I would think wearing bearings like that, and your driveshaft being true I would bet that there is a problem with balance or wear inside of the transfer case.
Just my 2 cents worth.