What i did the last time was with out moving i engaged 4 low shifted into rev./nut/dr then reversed the process stopping at each for several seconds then to park without moving an inch. thats what has me so puzzled.

 

Hopefully they will be able to figure it out then. Maybe your pressure plate isn't engaging correctly

 

I have had that noise before also and had no ill effects so far.

 

Isn't this Borg Warner T-case shifted by a little electric motor with plastic gears? If so, then it may have some goop gumming it up and not making the trip all the way back to 4Hi. Just a thought...I MISS my shift levers!

 

UPDATE,
Dealer called today and said they pulled transfer case 3 times, pulled transmission tore down and replaced some worn parts. still has the same noise. they said they have 3 06 models there and that all three do the same thing. Idk. they did tell me it is probably due to the motor being torqued up so tight that if i go from nutrual to park it does not do it.they also said that if it fails they will replace complete tranny. sounds like bs to me but its at their expense.