Is it fully engaged into position? Do you shift from high to low while in gear? I once grinded my Tcase in my K5 (np208) because i left it in gear...now i always shut the engine off before shifting into low. I think N will even still cause it to grind during the shift(friction drag?). My friends is doing the same problem yours has and while im no expert i think its because hes been shifting while in gear.
Anyone else want to back my statement up, or tell me im wrong?