It shouldn't make any nose engaged or disengaged. ANy chance it is a grinding sound? That would be really bad. Be sure that whoever you take it to documents (PHOTOS!) the disassembly, condition of the gears, etc. It sounds like you might have some expensive repairs that warrant a lawsuit on "bozo the mechanic", assuming he refuses to do the right thing from the begining.
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2003 Liberty Sport 4X4
DIY Frankie Lift, BBS Rims, Aussie Locker Rear, DTT Front, Renegade Rack & Light Bar, Custom Front Bumper w/ Warn XD9000i, Custom Rear Bumper, JBA UCA's, Full Skids(Mopar, Kilby and Super skid), CRS Rock Rails, CB, EVIC, Nav, power dim mirror, (2) 8" subs under front seats.
http://www.cardomain.com/ride/2512777