Finally have time to do an inspection of my suspension and steering system under my '91 xj and wow.

Here is an example of what I've found:




I don't think the sway bar end link bushings are supposed to look like that!

Looks like I have my next weekend project. Swap out all sway bar end links, replace sway bar bushings, etc.

 

I've seen a lot worse. They're not even cracking yet. Actually, it looks like your end links need to be longer so that the bushings meet the bar end on a flatter plane and not at such an angle.

Do you have a lift? Is your Jeep sitting on the ground in this picture? Sitting on the ground, your swaybar should be more level.

 

It's sitting on jacks but I do think the links need to be longer. I put the jeep back on the ground and there was still that bend. I also noticed that my drag link end was not looking good. I've noticed a bunch of klunking when I turn so this may be my culprit.

 

See how the bushings mate level with the sway bar in these pics? This is how it should look while sitting on the ground. Your bushings don't look too bad otherwise. For the clunking, get your head under there and look around for any play in the steering linkages, track bar, etc. while you have someone turn the steering wheel back and forth.

 

eh why look for trouble. Drive it till one breaks, meantime order some good ones for a fraction of the cost off ebay. When they go you will know, POP every 10 seconds. However they can still look fine visually.

 

Bushing should be the same diameter as the washer, that's hella torqued.

 

Right, I agree that's over-torqued. As you can tell from reading my post I was illustrating the angle of the sway bar and unfortunately those are the best pics I could find. I should have just shown the top pic, and even that one looks a bit tight.

Edited.