Steering goes pop when wheels turned

[Rustfree, Termite Infested]

I have a 90 Wag with a D44 front axle and a 2" spring arch lift that has me stumped: When the wheel is turned in either direction it makes several popping noises from the front end. I figured it was from a bad ball joint so I upgraded 'em all with the new bearing type. Four hours later I have smoother steering but the pop is still there. I looked at the frame and can't see any cracks. The rest of the suspension is tight. Anybody got any ideas?

[BigPaul]

Try seeing if the steering gearbox is mounted secure to the frame. Check the fluid level, and possibly raise the front on some jackstands to see if it does it without the weight of the front end.
Once it's raised, grab the top and bottom of each front tire/wheel and see if there is any play anywhere in the linkage. I would think that if its not ball joints, tie rods, or the lube that fixes it, it would be the steering gearbox itself. Either that or the steering shaft may have a bind somewhere. This is easily fixed with some new rubber at the joint between the firewall and the bearbox.

[Bob Barry]

It could be the springs shifting on worn bushings (hard to see the wear). Another thing I just ran into on my Cherokee; the tie-rod was rubbing against the steering-damper bracket on the drag-link. Turns out the tie-rod was bent back (must have hit something while four-wheeling; ice in the water, I'm guessing)), causing this unnatural interference. You need somebody else to turn the wheels back and forth while you're under there so you can pin-point the source of the popping.

[Michael]

Also check your springs. They could be popping as well. Mine do it when it is wet.

[Baldy]

I second the notion of bushings...an over looked area...shackle bushings themselves. They usually don't make any noise when going straight, when you turn, worn bushings make a distinctive popping sound. Have someone turn the steering wheel while the jeep's on the groung and watch for movement of the leafs. HTH

Laz

[Rustfree, Termite Infested]

Found it! The frame has a crack right above the driver's side swaybar and the steering box is pushing it apart when the wheel is turned. I'm going to weld it up and also install a steering box brace like the CJ folks use. There is a universal kit that fits Saginaw boxes and I will fabricate a rod to the passenger frame rail. Anybody else have probs with cracks in the LF frame rail?