Took it back in this morning. Service guy comes up to me and starts blaming my truck that the lift kit might be doing/ causing this popping to happen.
I look at him and tell him "there's no lift kit on that, it's roughly stock height"
unreal!
So he takes it for a spin and comes back to me and says nothings happening and asks me to show him.
I jump in with him and drive to the back of the dealership, put it in 4H and drive forward a few feet "POP"
put it in reverse "POP"
back into drive "POP"
I look at him and ask "you need more proof?"
he looks at me and says "yeah that's not good, I'll get my guy right on it."
It's amazing how they are always quick to blame everyone else but themselves for doing a poor job.
Guaranteed the mechanic forgot to do / align something in the transfer case when he put my transmission back on my truck.
Now I'm dealing directly with service managers, we'll see what happens next.
Fingers crossed!