Briefly (since there is apparently zero interest in this thread), I chatted with a Focusrite techie and found the answers:
1) Line out 3/4 never works outside of a DAW. They says it is a "limitation of windows" that audio can only be sent to line 1/2, although that seems a bit silly, since Windows happily allows multi-channel output for surround-sound cards. Regardless, the rule is this: if you want to use line out 3/4 you need to use Sonar.
2) To get Sonar to send audio to line out 3/4, select "Focusrite USB ASIO Output 3" instead of "Focusrite USB ASIO Output 1" (which is for line 1/2) as your output in Sonar.
3) Line out 1/2 is used for the balanced 1/4" outputs, the unbalanced line out 1/2, and the headphone jack. The headphone volume is controlled via the headphone knob, and the other 1/2 outputs are controlled by the Monitor knob. They are all working for me.
4) I think the reason I wasn't hearing anything on line out 1/2 earlier is I didn't want to crank up the Monitor knob too much, so the signal was so faint that I couldn't hear it.