I finally found a loud clunking noise in the Jeep. It has been driving me crazy for three months. It turns out that it was one of the lower rear shock bolts. I had to break the bolt to get it off. Since it is a ½” OD bolt I used a breaker bar and ½”-drive sockets. Once off, I could see that the outer diameter of the bolt had worn down to a much smaller size. When I would hit a bump, the shock would travel in the slop first, before compressing and doing it’s normal job. This created a clunk clunk clunk. I cannot explain why the bolt wore so badly. The shock only partially rotates around this bolt by a couple of degrees. Maybe rust and dirt get in there?
greasefingers
yea...real hillbilly setup on the stock set-up. I got them on good & tight with some of my own tricks. It aint going nowhere now.
The stock bolts are 12mm tapered...don't ask me why they are tapered. 
Had the same thing happen. Pressed some new 5/8" hourglass poly bushings in the shock hoops. Then pressed in some 1/2" ID bushing sleeves out of a Rancho install kit. Then finished up with 1/2" grade 8 bolts. Haven't heard anything from the rear suspension for years.
Link to bushings 9.8107
http://www.energysuspension.com/pages/sk_bsp1.html
Had the same thing happen. Pressed some new 5/8" hourglass poly bushings in the shock hoops. Then pressed in some 1/2" ID bushing sleeves out of a Rancho install kit. Then finished up with 1/2" grade 8 bolts. Haven't heard anything from the rear suspension for years.
Link to bushings 9.8107
http://www.energysuspension.com/pages/sk_bsp1.html
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