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One of the reasons I want to see an actual failed front diff (from 335xi) is to see if it was a mechanical failure, or lubrication failure, overheating, ring and pinion gears stripped, CV splines strip, etc.
To your point on the .5 pints of fluid, if they were failing on road courses or normal driving then I would tend to agree that this is a huge failure point... But it sounds like a lot of failures happen on hard or poor launches (again hard to find first hand examples).
The plastic gears are in the actuator housing, which seams to have more failures at higher power levels (though stock is common too). It sounds like the failures are from having to switch from RWD to AWD more quickly and thus strips the gears faster. I haven't really seen/heard of transfer case failures, but lots and lots of failures in the actuator planetary and worm gears.
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