Well, my weekly report on this issue has no resolution.

I rotated the rear driver side spring back to the recommended position (bottom tang facing forward) and added beefier spring retainers. I thought for sure this would solve the problem, but alas, it did not.

I am going to do a ball joint check this weekend even though they are brand new. While the lowers pressed in fine, the uppers were a very light press. That may have something to do with it, but I'm not holding my breath.

If that doesn't work, I may just assume it is supposed to sound like that until something breaks and fix that. I don't know what else it could be.

 

Wishful thinking

Revisiting this thread. I'm confused, is the sound from the rear or the front? Seems like you've been talking about both ends.

A lot of times when you get a pop turning in to an off camber situation like you described (turning up in to an incline), you can recreate the sound by getting two hands on the jeep and just rocking the heck out of it. Have you tried that? When you said you totally disconnected the sway bar, was that only the front, or did you disconnect the rear as well? You've double and triple checked torque on all shock bolts right (seems like this was one of the things you added just before the noise appeared)?

The upper BJs sliding in a bit easier aren't going to be related to this. Those uppers take no load at all and wouldn't be clunking around. RareParts are the only BJs out there, that I know of, that split a bit of the load to the uppers.

 

Believe me, I know that is wishful.

I've recreated the situation pulling into my driveway on several occasions with the doors off and I am 75% confident it is in the rear.

I have stood on every corner of the Jeep checking for a squeak which I believe to be unrelated and coming from the new control arm bushings. I can spray them with WD40 and they quit making noise. So I have not been able to recreate the sound that way yet. I will give it another go this weekend.

When I disconnected the sway bar links, I did front and rear, but not at the same time. Do you think that would make a difference? Also, the sway bars were still mounted to the frame, but the links were completely removed.

Shock hardware is tight.

 

Standing or jumping on the bumper doesn't do a whole lot in regards to moving components outside of slight shock and spring compression. You can really get that jeep rocking back and forth just pushing it repeatedly with force from the side. I've recreated many a noise doing that, and it sure makes it easier to pinpoint as force is applied to many components in the process. Leave the sway bar links connected when you're rocking it....if it's any of those links you'll hear it immediately. Also, if it's not making noise rocking back and forth like that, then it seems like forward/backward and/or upward/downward travel is coming into play as well. Pinpointing noises is always a bit of trial and error and eliminating suspects one at a time.