Thanks guys... okay, the latest is the front diff mount broke, which then (I guess) resulted in some undue pressure etc on the transfer case
Just spoke with them and they've opened up the t-case and it needs two new pinions and something else (couldn't quite hear what he said!)... sooo, should have it back Wednesday afternoon / Thursday morning...

which is great as we have a trip on Saturday with our little club
I did point out that this is warranty repairs, and thus far they said "of course"

so fingers crossed they don't change their mind!!!
Cheers
JFF
