I've tried all sorts of different pedal pressures and I can't get it to clank or not clank consistently. I'm suspicious it has to do with drivetrain slack as mentioned above, but not in the tcase, but either in the rear end flange, or the driveshaft spline(s) for the slip yoke.
I'm gonna add another test for you guys, Instead of paying attention to brake pressure when you start the truck, pay attention to brake pressure when you park the truck and the auto parking brake engages. I often add brake pressure while the auto parking brake is engaging, it order to get it to hold the truck, as it still rocks into park if I don't touch the brake. I'm ocd about that stuff, and I'm always the person who puts the e-brake on, lets off the service brakes, and THEN puts a vehicle into park. It's just good practice, because doing the opposite (park fist, then let off brakes, then ebrake) does not relieve the parking pawl of the stresses of the vehicles weight when on a hill. I'm still playing with my data on setting the brake pressure when parking, if you guys wan't to add to it, that'd be great.