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Rumblings.....drive shaft...now transfer case?

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I have a 2004 Cayenne S. 46K miles.

When I start from a stop with a slight amount of acceleration, I get a 'thump-thump-thump' -- seems to be coming from the right rear.

This doesn't happen all the time. Just some of the time. Sounds very mechanical

I took it to the shop. They replaced the rear drive shaft and CV joint.

Well, although it is less frequent...it still occurs. So, I took it back to the same shop the next day.

Had the mechanic drive around with me and he definitely heard it.

They took it back in and said that it is coming from the transfer case. Said it really doesn't it when the gearing is put in low ratio.

Now...my tires are pretty worn and I had bought them with porsche OEM wheels used (went from 18" to 20").

The mechanic suggested that I change all of the tires and see what happens. Says that the transfer case is extremely sensitive to uneveness in the tires, etc.

I'll get new tires tomorrow, but that all seems a bit fishy to me. I read about a recall that was made on 2004 about the transfer case cracking or something.

I don't know. All a bit strange.

I bought the car used about 9 months ago with 41K miles. I bought an after market powertrain warranty (whew...) which covered the replacement of the drive shaft/CV joint and I guess would cover repairs to the transfer case too.

Any thoughts?

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