Ok so every time i replace a part in the front end, i think that i've fixed it but it always comes back. Here is the list of parts that have all been replaced within the last 2 months:
4 ball joints
3 tie rod ends
drag link
pro comp steering stablizer
NO front sway bar
wheel bearings
rustys superflex lower control arms
pass side axle side upper control arm bushing
rusty's adjustable track bar

The only thing i have left is is the other three upper control arm bushings and this damn thing will be pretty much new. I just did the UCA bushing on friday and it worked great till i hit a pothole on rt 2 in CT on my way to rhode island. I had to spend the rest of the trip on back roads below 45mph. Added an hour on the my trip. It wobbles between 45 and 50mph ALMOST every time. Once u hit 50+ it vibrates and shakes, when you hit a big enough bump, it will wobble again. Also it tends to do this odd vibration like i'm hitting bumps on the highway, it vibrates for a second then stops, then starts, then stops and so on. It also gets worse when turning on the highway as well. I'm going to replace the other 3 UCA bushings but i'm running out of patience with this thing again.

 

you didnt say anything about the track bar or track bar mount.. check that. and get this Iron rock off road double shear track bar

 

Yeah I didn't see anything about your track bar... Which is the number one cause of DW. Do that, get it aligned, make sure your wheels are balanced and the pressure is equal in the two front tires

 

your problem lies in your sway bar.

 

before someone deicides to say im BS'ing. just think of what its called a SWAY bar. i had dw with no lift with my front discoed. around 45 mph it would wobble like crazy. replaced swaybar and the links and bushing. never had the problem again

 

what exactly does a sway bar have to do with DW?

 

it keeps the front axle from swaying side to side or wobbling wichever term you want to use.

 

the sway bar has no effect on DW. all the sway bar does is keeps the body from rolling side to side on the suspension. death wobble is caused by something being lose, whether it being a tre, track bar bushing, etc (probably not a tre in this case lol). which causes the steering, or the axle to shift from side to side, in a violent motion. therefore, the sway bar will have no effect on it.

 

the sway bar keeps the body from rolling side to side, has nothing to do with the steering or axle wobbling.

EDIT: also, swaying, and wobbling are two different terms in this situation.



to the OP, have you pulled the axle side bolt out of your track bar bracket? they're known to oval and wallow out, which will cause death wobble. I'm currently getting death wobble right now, and that's my only guess to my problem after seeing how wallowed out the hole is. I would check that, and replace the bushing while you're at it.

 

just giving my opinion. didn't make sence to me at first eaither untill i replaced my swaybar links.

 

ok that's awesome and all, but it will not cause death wobble.

 

Might also check your steering box. The rod that connects to the pitman arm on my zj wiggles side to side when i turn the wheel and if I hit a bump around 40 to 45 I get dw. Everything else is tight. You could do the 98 Durango swap its stronger than the stock box.

 

I agree with The_ocho and 1996sportXJ. Check that out and hopefully it will take care of your problem.

 

Sorry, forgot to mention brand new rusty's adj track bar. It could be the steering box because I am getting more and more play in the wheel as this progresses. I know my front tires are unbalanced too. I did my own alignment as well. Rides straight down the road but I need to adjust out my LCAs a little more to get the caster right.

 

Get your tires balanced (with the correct pressure) and get an alignment professionally done.