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I have found that after I installed my Swaybar disconnects they became loose after about 500 miles and would clunk on one side or the other going over bumps. I would check the mounting points of each front shock as well as the sway bar end links.
 

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^ X2. If you haven't touched the track bar, the sway bar links are the obvious starting point followed by the shocks.

It's too soon for your ball joint to wear out unless you have driven it hard and off road frequently.
 

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Also check the Front upper control arm bolts where they bolt to the frame. Mine come loose all the time.....very annoying and will cause a clunk. Hit the brakes hard and come to a stop....then accelerate...does it clunk? Or on a sharp low speed turn...ie driveway...clunk? Mine is the upper control arms everytime. Need to make a 1/2 to 3/4 turn to tighten back up and all is good. I really need to use lock nuts to end the constant maintenance.
 

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Discussion Starter · #9 ·
I actually just installed stock sway bar end links after removing JKS quicker disconnects. I marked the bolts after torquing and they haven't moved. I have also double checked the torque to confirm. problem persisted before and after the end links were replaced... I appreciate the suggestion but I feel they have been ruled out as the culprit.

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Discussion Starter · #10 ·
I have checked all bolts in the suspension and all are tight. I ordered a full set of bilstein shocks (4600's). Further investigation revealed all the symptoms are symptoms of a bad shock. the current shocks were Rubicon take-off, though the seller claimed they only had a few hundred miles on them, who really knows their prior history. I know since I owned them they went from lifted application (leveling kit) back to stock ride height.

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Discussion Starter · #16 ·
The new drag link cured most of the problems. However I do still hear a thud, usually from drivers side, over medium sized bumps/road imperfections. The handling of my jeep seems ok, but this "thud" which I can describe on a metal on metal thud is really annoying. Not due for an oil change/service for a few thousand miles but what should I have them look at when I get back to the shop? Ball joints? I have crawled under numerous times and tried to find something loose to no avail. I'm going to try to jack it up and test the ball joints....
 

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same issue here, play in steering and it was replaced by the dealer under warranty, I just noticed slight play at the drag link/pitman area that I will ask the dealer to change/fix

no play should be there as far as I know.

here is the replacement part.
 

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Decided to crawl under and check torque/tightness and found this: http://youtu.be/VK-tYvJPaZ0 Is that amount of up/down movement ok, or is it worn (again)?
Just that joint ? I was reading somewhere that the stock Tre's have a spring that that small amount of play using channel locks is normal.
If it pops up and down doing the steering test, it's worn.
Trying to find the post now. I don't have stock steering anymore.
 

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Discussion Starter · #20 ·
Just that joint ? I was reading somewhere that the stock Tre's have a spring that that small amount of play using channel locks is normal. If it pops up and down doing the steering test, it's worn. Trying to find the post now. I don't have stock steering anymore.
Yeah the Pitman arm end of the drag link has no play....
 
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