[HUMTECH]

Sounds to me you may have A damaged range shift fork and it is not fully engaging into 4hi causing an intermittant bang from the t-case when loaded on A turn. The encoder motor rotates the shift shaft which moves the shift forks and if A fork is damaged or broken will not fully engage the range selected. No need to worry about pinion gear timing as the t-case was never apart if just the encoder was changed and if they were not timed correctly there would be constant binding in the t-case. Try all t-case ranges for proper engagement, if A fork is damaged you may or may not get all ranges depends on the extent of the damage.