It "only" happens at turning/low speeds...even straight? or does turning HAVE to be involved?
I'm not sure if I fully understood the difference..
Seemingly, if it was your TC, it should happen at high speeds and it would probaby get worse as the speed increased. (only because it doesn't whine does not mean its NOT the TC, could be different issue than most of us are use too)
If it needs steering angle, than most likely you are not looking at a TC issue, perhaps an axle issue with one of the CV joints....
When wheel bearings and CV joints are bad, they normally don't rotate smoothly like good parts would. I would disconnect the RR driveshaft and keep the FR off the ground as I tried to locate the issue by hand spining the wheels..... If all else failed, I would turn the vehicle on and let idle rotate the wheels and try that way.

Keep in mind only because the dealer did the install doesn't mean they didnt make a mistake, it happens all the time....forget to tighten things, cut corners.... things like that. (its just not 100% guaranteed)

 

What fluid is being used in the T-Case?

Josh

 

Thanks guys for the replies. As most of you mentioned, it couldnt be the TC since no chattering occurs at high speeds and it only happens when turning at very low speeds. I'm getting tired of the dealer's suggestions. They said it was from the clutch (highly doubted it in the first place) and now they say it's from the TC. They basically prove that they have no idea about fixing the problem.

 

I believe they use Diaqueen fluid.

 

By your descriptions, nothing I could understand would indicate your TC. It would see absolute minimal loads from any turning. I go back to my original suggestion.
Wheels turning + Steering angle combined = Axle joints (80% chance I calculated )
What other parts does it take for both of those things to happen at the same time?

If steering is a must in any case, it has to be connected some way shape of form. What parts are effected by steering alone? (we understand it is not interior parts )
Knuckle/spindle
Damper (because it twists while steering)
Steering rack & pump, etc
subframe (because it resist steering loads)
Axles
bearings (axial loads)
wheels
tires

Now think of any others... and then cross out the ones you KNOW it's not, especially the parts which they didn't have to take off to replace your TC
and remember, misassembly is always a choice.... is everything tight? your axle nuts?
They either had to remove the damper from the knuckle or the lower ball joint to remove the axles to get your TC out. Highly doubt they would drop your entire front subframe/engine assembly to do it.

 

Here is my suggestion, with the help of your friends push the car while turning and try to find out where the noise is coming from.

It might help you much more than going to the dealer and asking on the forum.