A 4 hour job by a trained mechanic.
Did the engine oil and filter change as well.
Cured the binding and the jumping into lock mode.
Total cost of $ 194, to include :

1- Shift fork , steel : $ 34
2- D III oil , 1.5 L : $ 20
3- Engine oil : 6L : Motul 5w40 : $ 54
4- Delco oil filter : $ 6
5- Labor : $ 80

The TC dismantling, cleaning and back together took 4 hours and was straight forward..

One advice though, mark the chain and sprokets, as we didnt and I have now a slight chain rattle , due to obvious wear ..Maybe it'll wear back in it's place, or not ..

 

it looks loose,GREAT PIX!.
depending on how long it was stressed,it and other stuff would wear.
something gotta give huh!

btw,seeing those pix reminds me how much i miss the good old manuals with
pictures you could understand

 

4 hrs huh!!

 

Nice job! You saved yourself a lot of $. i was wondering if that was a job i can take on at home. did you run into any troubles? How difficult of a job is it? Im assuming it would take me at least 8 hours. Haha.

 

This job was done by a mechanic at an independant garage. I just was at hand to make sure all went smoothly...Labor rates in Lebanon are cheap..That's why the job costs so little .
Even though , the local hummer dealer quoted $ 150 in labor which is still cheaper than the US.
The main thing is that I dont worry now about pressing those buttons on the dash

 

If you're fairly good at mechanics, you could do it with the right tools..it's not that hard.. assuming you mark everything and remember where everything goes.

You have to remove the protection under : engine, gearbox, TC and the metal bridge that runs under the TC.
Disconnect and remove all electrics from the TC, motor and speed sensor.
Empty TC oil.
Remove front and rear drive shafts.
TC has many bolts....remove all and open TC slowly..
Mark position of chain to sprokets and if possible the other sprokets in relation to their position.
One item to be carefull with is the metal shaft that switches between the different locking positions...This shaft has a small pin that links it to the TC..this pin can be lost, guard it carefully.

I also realised that there is no seal in the transfer case.. u have to use a sealant when you put it back together.. use a good one.

These are the things that i remember and are the most important in this job..
Hope it helps someone..

 

Forgot one essential thing..
You need this manual lift to hold the TC from underneath while removing shafts and so on..
And it's kinda heavy, so you'll need 2 people to carry it ...