Don't know if that's a BW or NV case. What modes do you have on the 4x4 shifter?
Could be a bad rear-output bearing. You may have thrown the chain. Any leaks?
As for cracking it open yourself, no rocket science involved, but transfer cases are a wonderland of snap-rings and seals. Plan on a day+ the first time you fix one. You could open it up and find you need $200 in parts plus time to flush it out and hope nothing else got munched.
Call yards in your area. Some of these cases are plentiful and cheap. If you buy new or rebuilt plan on $600-1200 for stock strength. Instead of rebuilding I've picked up low-mileage yard units for $100. At that price it isn't worth the time to buy a kit and install it for a daily driver.
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There are a vast number of people who are uninformed and heavily propagandized, but fundamentally decent. The propaganda that inundates them is effective when unchallenged, but much of it goes only skin deep. If they can be brought to raise questions and apply their decent instincts and basic intelligence, many people quickly escape the confines of the doctrinal system and are willing to do something to help others who are really suffering and oppressed." -Manufacturing Consent: Noam Chomsky and the Media, p. 195
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