Transfer case noise? Whenever shifting from P to D or to N or to R?

The tire size should not make a difference, it sounds like you have a transfer case actuator motor that is weak, if you upload a short video of the noise, I can tell for sure what's going on. Here is the location of the unit so you can change it out. Check out the images (below). Please let us know what happens.

Thanks for the videos, they helped. The fact that the noise occurs when not driving rules out and internal problem. Good job on the video find the control module must be mixed up causing the actuator to oscillate. Here is the location of the module in your car so you can swap it out. It look like it is a plug and play part so that is nice. They do have a relearn procedure but if you just drive it you should be okay. Here it is below and please check the images below.

TRANSFER CASE VERIFICATION TEST

1. Disconnect all jumper wires and reconnect all previously disconnected components and connectors.
2. Make sure that all accessories are turned off.
3. Make sure that the battery is fully charged.
4. With the scan tool, record and erase all DTC(s) from the Drive Train Control Module (DTCM) and the Cluster/CCN.
5. Test drive the vehicle. If equipped with a selector switch drive the vehicle in each Transfer Case range and verify proper operation in each range.
- To select or deselect 2WD, AWD or 4HI mode, vehicle speed must be below 88 Kmh (55 mph) with all wheels at vehicle speed.
- Shifts will not take place with a wheel speed difference of greater than 21 Kmh (13 mph) between the front and rear wheels.
- To select or deselect 4LO (if equipped), vehicle speed must be below 5 Kmh (3 mph) with the ignition on, engine not running and the transmission in neutral (automatic transmission) or the clutch pedal pressed (manual transmission).
- To select or deselect Transfer Case Neutral (if equipped), vehicle speed must be 0 Kmh (0 mph) with the ignition on, engine not running, the brake pedal applied, and the transmission in neutral (automatic transmission) or the clutch pedal pressed (manual transmission). Press the Neutral button (if equipped) on the Transfer Case Selector Switch until the Neutral Indicator is illuminated.
- WARNING:
Apply the parking brake. The vehicle may roll with the Transfer Case in neutral.

- To verify that the Transfer Case is in Neutral, shift the automatic transmission into reverse and release the brake pedal for three seconds or shift the manual transmission into gear and slowly release the clutch pedal. There should be no vehicle movement if the Transfer Case is in Neutral.

6. With the scan tool, read DTCs in the Drive Train Control Module (DTCM) and in the Cluster Control Node (CCN).

Check out the images (below). Please let us know what happens.

The transfer case motor is the item that is making the noise but that is because of the TCM shorting out internally. The new TCM should fix it. Let me know.

Are the tires the same size? If so, you should be okay. Can you tell if the noise is coming from the same area? If so, I would try to service the transfer case and install fresh gear oil.

Fluid Types

TRANSFER CASE FLUID

MP2010 .................... Use ATF approved to MB 236.10, MB 236.12.

MP3010 .................... Mopar ATF+4 Automatic Transmission Fluid

MP3023 .................... Mopar ATF+4 Automatic Transmission Fluid

Capacities

TRANSFER CASE FLUID CAPACITY

MP2010 .................... 0.51 Liters (1.1 Pints)

MP3010 .................... 1.35 Liters (1.4 Quarts)

MP3023 .................... 1.9 Liters (2.0 Quarts)

Caution: Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerance and refill procedure.

Here is the job being done on a similar car, but the procedure is the same:

https://youtu.be/jywt228y8UM

Please check the images below for more instructions and let me know how it goes

Thanks for the videos, most of the noise seems to be gone, I would service the transfer case which should take care of the remainder of the problems. The transfer case is a normal service item so you have nothing to lose. Also do you have any warning lights on?

Okay, let me know once you have serviced the transfer case.