Lound Noise While Shifting Into 4wd

[KB10]

I own a 2005 F150 STX 4X4 (4x4 is manual shift) Recently I took it to Ford to check out a noise I heard while in 4WD. An unusually loud rotational noise coming from the right front. They road tested and verified the noise and overhauled my transfer case as their repair. Got the truck back and still the same noise. But now, along with the rotational noise, my truck has a slight vibration to it while in 2WD and when I shift it into 4WD I hear a loud "clunk". Sounds like something is not engaging properly in the transfer case. Took it back to Ford and now they are trying to say that the rotational noise is normal and that the loud clunk is also normal. WHAT???? Are they kidding? The truck never made a peep while shifting into 4x4 prior to them overhauling my transfer case. Has anybody had a similar problem? Does anybody else who owns a 2005 STX manual shift 4X4 hear a loud noise while shifting into 4WD. If not does anybody have any advice on how to handle the situation. I think the dealer is giving me the run around. What is the best way to get into contact with someone at Ford who actually would want to help me. I'm still under the 36,000 mile warranty. Thanks

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[glc]

Take it to a different dealer.