Clunking/Popping while turning
 

Hello everyone, first time posting so if I put this in the wrong place I apologize.

My XJ is a 1998 sport
4.0L
AW4
iron rock long arm lift kit plus rusty coil springs making about a 7 inch lift maybe 7.5
SYE kit
Geared to 4:56, 35 inch tires
Bunch of suspension joint upgrades and what not, relevant to this issue is the JKS adjustable track bar

So I have narrowed this clunking noise while turning (more prevalent when slow or at least I hear it better) to the track bar mount bracket area. I will attach a video, but you can clearly see the track bar shifting laterally when you hear the noise. The things is, I have tightened these bolts holding the bracket on to the frame before with loctite, they are super tight (just checked). Yet the whole bracket still seems to be moving. Curious if anyone can see what my problem is from the video. I was suspecting maybe the bushing where the Track bar meats the mount. It has a grease zerk so I filled it up but the did not help. Any advice appreciated.

Agreed that the whole bracket appears to be moving. I would suggest disassembling the components and taking a look in the area for a cracked or broken metal piece. Since it appears that there is play, I would check torque specs and retorque all bolts after the disassembly.

As in like a cracked metal piece from the aftermarket bracket? I also remember reading something about the hole for the bolt from the track bar gets like carved out or something weird. I keep wondering if it is that or just the bushing has gone bad or something in that area because the mount seems fine from me looking at it. You thinking I should pop the track bar off the bracket and get a better look?

If I do not see any visible metal cracks what are some signs that bushing might be going bad. Also thank you for your response.

Ok i pulled the track bar off to inspect arpund but dont see anything out of ordinary. Will attach photos.
https://cimg6.ibsrv.net/gimg/www.che...d610ebd4cd.jpg
https://cimg8.ibsrv.net/gimg/www.che...a3b40c4858.jpg
https://cimg0.ibsrv.net/gimg/www.che...48d3e4dd36.jpg
https://cimg1.ibsrv.net/gimg/www.che...9246e07ba1.jpg

That track bar mount is loose, probably the ID of the bolts is nowhere near the OD of the holes at this point. If nothing is broken with the mount and frame then bolt I back on there and weld it in place ;)

Yeah you might be right. I took the bottom holes off and check out how bad they look....

Would welding it hold up off roading lmao
https://cimg5.ibsrv.net/gimg/www.che...ff94d0bebe.jpg
https://cimg6.ibsrv.net/gimg/www.che...cf46dcad9c.jpg
https://cimg7.ibsrv.net/gimg/www.che...91cba02ff0.jpg

Yeah, those bolts are way small for that and I doubt you'd ever get them tight enough to not come loose. I'd probably plug weld right in the middle and then around the out side of the bracket with it all aligned and bolted down tight.

Even though they feel tight? I mean they were tough to get on didnt feel loose or strippe. At least when i put a wrench on it and felt them

The video shows it moving, They were not tight enough to hold the bracket in place. I don't think those bolts can be tightened enough to keep that bracket from moving. If it were mine, I'd weld it on, but that's me.

Yeah thinking maybe ill get a double shear bracket. Dont have a welder and my buddy thay does lives an hour away.

Where in CO?

I just moved to Denver i was up in fort collins thats where friend with welder is. I ordered a new bracket anyway and a track bar. Figured screw it now i have an IRO lift arms and track bar/bracket.

Ok, the whole mount is moving. I see there are no washers under the bolt heads, that is a big problem, get some good hardened washer, use grade 8 (SAE) or 12.9 (metric) hardware. You should tighten the bolts and nuts to the specification for that type and size of bolt. the factory specs for the jeep may not be that high, and you will need more force for your modified jeep, you are putting much more stress on the parts with wheeling than for stock use. Is that bracket stock? Maybe you need to get a beefer bracket too, but first thing is get the best high grade nuts and bolts and washer, use over sized if possible (drill the holes as needed bigger) you should redrill the holes to be a tight fit for the new oversized bolts. Note those bolts appear to be SAE, but I think the jeep frame is mostly all metric, so maybe those SAE bolts are under sized for the metric holes. solution is to redrill bigger for the biggest bolts, be it metric or SAE.
Mine made a similar popping noise, it was a loose bolt, that was it.

Here is a bolt torque chart for SAE hardware ...
https://mechanicology.com/sae-bolt-t...rade-5-grade-8

and for metric hardware...
https://mechanicology.com/metric-bol...0-9-class-12-9

that bracket needs the #@$% torqued out of it to hold in place with your big tires. thus use only highest grade hardware with hard washers, and when possible drill for over sized if stock diameter keeps comign loose, use the maximum torque per the linked charts for bolt/nut combinations you use.

I also like to put a little contracting paint mark around the heads to I can easily see where movement has happened. After big wheeling trips, I like to go around and recheck the torque on some of the hardware.

anyway, torque them down with correct hardware and washers!!!!.

also it appear that one of the nuts in your photos is a crimped locking type, these are designed to dig into the external threads on the bolt or stud. After use, that bolt or stud should be replaced to assure continued locking action. use of a lock washer and or lock tight can be helpful. Note that lock tight can give a false impression of tighteness, in that it maybe very difficult to retighten, so you think it is tight, when in reality the joint has been shifting, it just is the nut is well lock tited to the bolt, but the clamping force is not there anymore.

Yeah got an IRO track bar with double shear heavy duty bracket on the way. I used a dewalt impact to tightsn those down they cant get any tighter without breaking. I think its the bracket itself honestly. Worn out around the bolt holes from constant movement. Ill attach a pic i took of the bolt holes.

I suspect the new one will fix everything but ill post an update after i install it. Anyone else having a similar problem should check their bolt/holes, off roading and time does a number on them.

https://cimg2.ibsrv.net/gimg/www.che...88e121e87b.jpg
https://cimg3.ibsrv.net/gimg/www.che...9f6a2985e4.jpg
https://cimg4.ibsrv.net/gimg/www.che...5f73cd9f1a.jpg

You can see where the bolts have pressed the threads into the sides of the holes. Those bolts seem very under sized for what you're asking from it.