Well... I've gone throught everything I can think of, and I can't find it. So, I'm going to ask for words of wisdom here.
I have a clunk when I hit bumps in the road. Big and small... even small ones make the noise. It seems to do it on the downtravel.
I see no signs of anything touching or rubbing anywhere in the range of travel with the Jeep on the ground, bouncing on the bumper, or on the lift, raising and lowering the rear-end with a transmission jack. I can't make it duplicate the noise unless I'm driving down the road.
It almost sounds like the wheel is wobbling on the hub, but I KNOW that's not the case or it'd do it all the time, not just when I hit a rough spot in the road. I also went back and removed the little locks off of the rotors and reinstalled my wheels after the shop failed to removed them when they put my aftermarket wheels on.
Things I've checked:
Shocks- The stock ones were all tight and didn't have issues. I replaced them with OME this weekend... clunk still present.
Track bar- Both bolts were tight. Installed Terraflex bracket this weekend... clunk still present.
Sway bar- Links weren't touching anywhere, replaced with 2" longer ones this weekend to compensate for lift... clunk still present.
Bumper- Checked bolts for tightness... clunk still present.
Subwoofer/box- removed and rode around without it in the Jeep... clunk still present.
Brake rotor/caliper clearance- All appears to have plenty of room, and I'm not hearing the noise on the passenger side.
Spring- Its sitting in the factory rubber perch up top, and isn't contacting the body anywhere. I've even rotated it and re-positioned it on the axle to see if it changed anything... clunk still present.
Exhaust- I've gone up under there and pulled/pushed on it and don't feel it rubbing/hitting anything...? The noise doesn't sound like a heat-shield at all. It's more of a clunk, not a tap.
So the problem is in the rear wheel-well area somewhere, but for the life of me, I can't find it.