Pulled the shifter unit again and played around with the arm to see how its position responded to the actual shifter. It's very sensitive in the 'cross' gear from D to 4th and back again. If there's any load on it it'll bind and make that secondary 'click' noise. I shimmed a few mm in the rear of the shifter during re-installation to adjust the pitch...works smooth as a button now which is how it is supposed to be. New function is
HERE.
Hope this helps!