Click/clank/clunk after front axle swap

[Some Random Guy]

Ok, so I swapped in a UD44 front for my M186 and used the stock draglink and a metalcloack tie rod. The jeep already had all around adjustable control arms and adjustable track bars from metalcloak. I did the MC 2.5” springs at the same time. First 100 miles was fine. Dialed in caster to 6 originally and 1/8” toe-in. It recently started making noise up front. I can usually feel it in the footwell through the body, but occasionally I get a similar noise from further back and feel it in the seat. It is related to loading/unloading front/rear suspension and possibly lateral loads make it worse.
I thought I mistorqued something, turns out I missed front track bar axle side. Noise still there. I regreased the tie rod, better for a bit but keeps coming back. I might have a bad boot:

Jeep also settled and was running crazy high caster. I fixed that last night and re-greased the tie rod again. Noise still there. I also discovered my front driver spring was unindexed axle side, fixed that. I thought maybe that was the noise because there is no isolator on the UD44, it is metal on metal.
I still don’t have my steering stabilizer on because I wanted alignment dialed in first. I also have to reset toe and re-center steering after last night’s caster/pinion change.
My next steps are:
Replace track bar bolts. I was already planning to, I just forgot to buy them while swapping axles. I will start with the front and if that noise goes away I will do the rear.
Could I have a bad ball joint from the factory? How do you test it? I know they’re torqued down enough because much more and the cotter pin won’t hold the nut.
Maybe it is the tie rod end, since greasing shuts it up for a day and then I get that goopy mess.
Any other ideas?

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[DOOKEY]

Engine off-Acc. On to unlock steering wheel. Have someone crank the steering wheel back and forth to change directions. Keep repeating. Get under the front end and see where the noise is coming from. If you can't find it that way put the Jeep in 4low with the foot on the brakes. Shift from forward to reverse again and again. That will make the pinion roll up and down which will check your suspension arms. If you can't find the noise there I'd start to believe ball joints. Have you torqued them properly after install?

 

[Some Random Guy]

Engine off-Acc. On to unlock steering wheel. Have someone crank the steering wheel back and forth to change directions. Keep repeating. Get under the front end and see where the noise is coming from. If you can't find it that way put the Jeep in 4low with the foot on the brakes. Shift from forward to reverse again and again. That will make the pinion roll up and down which will check your suspension arms. If you can't find the noise there I'd start to believe ball joints. Have to torqued them properly after install?

Yeah, I torqued them to spec. The weird insert on the top joint made me think I had messed up, but if that insert were pushed flush up top the cotter pin would become worthless.
I got it to make noise sawing back and forth while idling today, so I do suspect something steering (track, tie, or knuckle).

 

[DOOKEY]

Yeah, I torqued them to spec. The weird insert on the top joint made me think I had messed up, but if that insert were pushed flush up top the cotter pin would become worthless.
I got it to make noise sawing back and forth while idling today, so I do suspect something steering (track, tie, or knuckle).

If your can hear it while sawing back and forth it should be easy to spot once you get under there. Watch the frame over the axle. If your frame moves side to side over the axle then your track bar is the issue. You should be able to see what's going on if there is an obvious clunk.

There are lots of different issues that can pop up so check the bolt is tight on each end. Make sure the bolt doesn't flop around in both sides of the bracket holes. Make sure the track bar end isn't moving over the bolt inside the bracket. Then check the bushings themselves for play.

 

[DOOKEY]

If you don't find it in the track bar start at the steering gear and work your way down. The gear needs to be tight to the frame so check the bolts. Check the pitman arm on the sector shaft and make sure it is tight on the splines. Then check the rod ends in the pitman arm. Check the turn buckle to make sure it is tight. Then the joint at the knuckle. Sawing back and forth will hopefully let you find it.

Then move to the tie rod. Same gig. Rod ends. Adjustment buckle.

 

[Roky]

Yeah, I torqued them to spec. The weird insert on the top joint made me think I had messed up, but if that insert were pushed flush up top the cotter pin would become worthless.
I got it to make noise sawing back and forth while idling today, so I do suspect something steering (track, tie, or knuckle).

I think you answered your own question, if globing in the grease calms it down, I’d start there…and apparently globing is a word as I did not get autocorrected….. ?

 

[Some Random Guy]

Track bar bolts didn't help.

I think you answered your own question, if globing in the grease calms it down, I’d start there…and apparently globing is a word as I did not get autocorrected….. ?

Yeah, I'm just hesitant to blame a brand new balljoint on the tie rod. I'll contact MC and see if they've got suggestions on how to check it.

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