I had the same problem about 8 months ago. Fixed it with a wrench. It didn;t come back yet.

Get a wrench and set the lower intermediate shaft bolt tight to death.

 

I wonder if anyone would be willing to do a small tutorial video for the grease fix. Even if it was just the syringe method I'm sure it's help a very significant number of people and wouldn't be too difficult to do. 2 out of 3 of my JKs have had this issue, all low mileage. The third luckily only had stock death wobble.

 

My intermediate shaft was replaced 1.5 years ago and now the clunck is back. Greased the shaft and the clunk is still there.

Any word on a aftermarket shaft.

 

I posted this in another similar thread but noticed this one was quite a bit more active so I'm gonna post it here.

In the warn weather or even in the cold weather after a while of driving (allowing the bay to heat up) my clunk comes. This is typical of the intermediate shaft. When it's very warm it can get pretty bad, I will also feel it in the brake and gas pedal sometimes. Like a slight knock in the pedal at the same time as the knock in the steering wheel

I've read this is very common among people having the steering clunk, but seeing as how my knowledge of the front end is lacking, can someone explain to me how the pedals can be affected too?

Also, what are symptoms of worn balljoints as opposed to the intermediate shaft problem?

 

My problem is the exact problem you are having with all the symptoms

 

+2

One intermediate shaft replaced already. Got about 28K on the ticker, will go back for warranty work soon.

 

Called Borgeson sales and there is no plan's at the moment to make a new streering shaft for the 07 and up

 

dealer replaced intermediate and upper shaft today no questions asked. Feels completely different.

 

So this is it, I never been off-roading. Notice it around town and slower speeds once the engine is warm. I just wiggle the wheel and feel and hear a clunk like a slight knock in the pedal at the same time as the knock in the steering wheel.
Man I'm happy to have found this post because I've been taking my 2008 Sahara in to the dealership for over 10 mouths now telling them about this "Clunk" which they cannot see or hear (They thought that I was just an fussy client getting frustrated with small cracking noise coming from the dashboard) . so once it stated to do the noise again I had to quickly drop in to the dealership and get a mechanic to come and hear it (he agreed that it was an annoying noise) so I left the vehicle there to see if they could fix it and they told me at the end of the day that it was normal and I replied that it's not normal if it gets on my nerves!
I will try to get them to read this bunch of stuff from the service manual on this issue
RATTLE OR EXCESSIVE CLUNK**
1. Power steering gear loose on engine cradle/crossmember.
1. Check fastener torque and tighten to specifications. Replace as necessary. Check steering wheel center following repair.

2. Loose strut assembly mounting fasteners at tower or knuckle.
2. Check fastener torque and tighten to specifications.

3. Excessive play in outer tie rod.
3. For evaluation…

Thx OP for this thread!!

 

So here it is. I have removed the intermediate shaft from the jeep to further diagnose the problem. I removed the boot and greased the heck out of the spline shaft as much as i can getting the grease inside while compressing the shaft. (use hands and compress - decompress while adding grease multiple times.) Re-attached the boot using zip ties and re-installed in jeep. The clunk is gone. I can't believe it. Since you cannot get the spline shaft completely out of the intermediate shaft, i can't be sure but, there must be rust in there and acting like sandpaper while the shaft compresses causing a clunk.