no oil in the transfer case is really bad. They have a bad habit of seal leaks. You probably haven't had any fluid in there for a year or more.
These units can be rebuilt with all new stuff (bearings and seals) for around the same price as what you're talking about to get a used one:
http://www.brickboard.com/AWD/index.htm?id=1376357&show_all=1
Your symptoms don't match up in my head though - no AWD with no other symptoms/noises/vibrations doesn't sound like a wrecked bevel gear to me. Sounds more like the haldex wasn't working right. Maybe you were having some other noise/problems.
If your bevel gear still had fluid in it I would say to just have the outer seals changed, the vent cleaned/replaced, and the fluid flushed - but I would be worried about the bearings in your particular case. Those bearings get their lubrication/cooling from the case fluid, as do the gears themselves...
If I were you I'd probably spend $15 on some oil and start from there. If you find a leak then fix it (seals). If your problems persist then you will be able to start working back from there.
You can remove the bevel gear completely and go from there as well if you choose. There are posts on this board and others that describe this process.
Removing and installing the bevel gear is not a bad DIY job that would save you some money in labour. If you're looking to do a rebuild you can then take the gearbox to the trans shop yourself.
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