Guys, I'm new here, but I'm at my wit's end and hoping I can find some help.

I have an unidentified clunking coming from the front end of my 1996 XJ (4.0L, SE). It clunks when the steering wheel turns, as the wheel turns. It also clunks when I go over bumps.

I have disqualified the following by replacing them all with new this weekend: all 4 balljoints, half shafts, and full new steering linkage (from pittman arm to steering knuckle), all new shocks, all new tires and 4 wheel alignment.

My local shop has no new ideas. Everyone says bushings, but it feels and sounds mechanical. It's very predictable, makes the noise whether I'm moving or not, and the noise is worse in certain wheel positions than others.

My only thought is that my steering gear box is worn out and the teeth are slipping, but I've never had that happen before. Does anyone have any ideas before I throw more money at this problem?

I greatly appreciate the help.  

The steering shaft connects the steering column to the steering box. Just down from the firewall there is a joint that wears out.  

ftgiles, I had actually wondered about that. It doesn't seem too difficult to replace, looks like 2 clamp fittings at either end. I just stayed away from it, as I've never heard of a steering column wearing out.

How difficult was that fix when you performed it? Did you do it on a Jeep with Airbags?  

Jeep420 had the same issues with his YJ. Replaced everything and it didn't fix the clunk. It ended up being the joint on the steering shaft.

Send him a PM or maybe he'll respond here...  

Thanks for the advice. I'm still striking out... I replaced the track bar on it last night, b/c the clunk stopped once I disconnected it, then once the new one was installed, the clunk started anew.  

Hate to bump my own thread, but I'm in need of help here, if anyone will take pity on me.

So far we're up to: new balljoints, new tie rods, new trackbar, new shocks, tires and alignment, and as of last night, a new steering gear box (on the advice of a Jeep dealer). The clunk persists. Additionally, my steering is getting progressively more vague the more I do to it.

Has anyone has similar experiences with an XJ, or any thoughts at all? Thanks in advance for taking a look at this.  

dang!  

Dang is about right, at this point anyway.

On another topic, if anyone's interested in a 96 XJ with a completely rebuilt front end and a *barely* noticeable steering clunk, PM me.  

how bout the pump? i hate to throw gas on the fire, but since you already put all that money in so far.......why not drop in a new pump. you say you did replace the joint on the steering shaft? did you greese it?  

I did grease the joints, all of them in fact.

I thought about putting a new pump in, but it's running fine, and maybe I'm missing something, but a bad pump wouldn't make noises over bumps, would it?  

The joint on the steering shaft? The shaft between the column and the box. Did you replace it?  

I did replace the intermediate shaft while I was in there. I figured it out at about midnight last night. One of the holes for the trackbar bracket had ovaled (I believe the technical term is "wallered") out, and the bracket was shifting maybe 2mm in either direction under stress. I only found it through the help of a mechanic from a different dealer. I just plugged a crush washer in, torqued it down as tight as I could with a 3ft breaker bar, and we're all done.

I'm relieved that it's over, but I have to admit I don't feel very bright right now.  

Now you won't be pull'n your hair out trying to figure out your death wobble problem... That is the number one cause of death wobble too. Good Job!