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If you can still make it happen on the jack stands then start taking it apart.
Your video sounded external to me. A sharp noise, not muffled like inside the housing.
Driveshaft off, still there? Take the wheels off try again, take the calipers and rotors off, still there?
 

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Discussion Starter #22
Update

If you can still make it happen on the jack stands then start taking it apart.
Your video sounded external to me. A sharp noise, not muffled like inside the housing.
Driveshaft off, still there? Take the wheels off try again, take the calipers and rotors off, still there?
The Jeep is fully assembled right now. I am baffled because before I replaced the ball joints, u-joints, and Hubs I drove the Jeep for a bit with just the small drive shafts and took the inners out. While waiting for the parts to arrive... I experienced the same binding motion and noise (it’s enough to cause the Jeep to move differently). You would think it is in the drive train by the way it acts, however, the issue happened even when the axle shafts were out so that is the confusing part. Nonetheless, I can temporarily fix the issue if I pressed the brakes. At this point I was thinking it was the hub for sure... so I replaced all the parts a few days ago and thought it was fine, however, it is not. Its come from the passenger front. I have replaced all the major parts in the area. I am wondering if it may be the brakes. I am letting the Jeep sit for two days and I am going to mount a camera on the front to see if I can record what is going on. I have thought about putting it on jack stands again as well. The weird part is the issue pops up only after the Jeep sits a day or two. If I regularly drive it... doesn’t really become an issue. I thought about letting it sit two days (to get the issue to happen) and then just driving it to the point of part failure instead of pressing the brakes. I am ready to know what the issue is so I can fix it and call it a day. I’ll follow up after I make the video.
 

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..... I am wondering if it may be the brakes. I am letting the Jeep sit for two days and I am going to mount a camera on the front to see if I can record what is going on. ....
As I was reading I immediately thought about brakes, then you mentioned it. I know some here have reported dragging calipers/pads - you might look over those threads for similarities to your issue.
 

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As I was reading I immediately thought about brakes, then you mentioned it. I know some here have reported dragging calipers/pads - you might look over those threads for similarities to your issue.

I never had noise associated with my dragging brakes. Severe death wobble around 48mph, yes, reduced climbing and acceleration, yes.
 

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Discussion Starter #26
Just curious, has the sound changed at all in tone or volume? Does it happen in reverse? Wonder if it will make the sound with the rotor removed?
It’s more of a binding sound. It doesn’t sound like the video I posted. I’m thinking this problem is a conglomeration of several problems... which I have fix some of them. I believe I have fixed the noise that is shown in the video with the replacement of the locker. I have not tried removing the caliper yet. However if it persist I will. See below.

..... I am wondering if it may be the brakes. I am letting the Jeep sit for two days and I am going to mount a camera on the front to see if I can record what is going on. ....
As I was reading I immediately thought about brakes, then you mentioned it. I know some here have reported dragging calipers/pads - you might look over those threads for similarities to your issue.
Thanks. I will look more into it... In fact that may be it. So I just fired up the jeep after letting it sit a few days and it drove normally with no issues. Of course the video was rolling so maybe I am just not lucky enough to catch it. Before I parked the jeep a few days ago I cleaned the metal surface the brake pads slide along because it was very dirty and gunky. It has yet to make the noise since two days have past since cleaning it. I’m hoping that’s it. Time will tell and I’ll keep posted.
 

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Discussion Starter #27
Well. Jeep is still making the noise as of the morning. Normally it has to sit a few days. However, it ended up making the noise the morning. I managed to get a short video (link below). After holding the brakes and driving a few feet the noise cleared up. I am going to try pulling the rotor and caliper from the passenger front to further trouble shoot.

The video:

https://youtu.be/sX8u46AtP4c
 

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Sure sounds like Gear noise. Did you replace your ring and pinion when you changed your 3rd member?
If you disconnect your front drive shaft does the noise go away!
How about if you turn it by hand?
You might also check your unit bearings.

FWIW, my buddy had an 06 LJR with the exact same front diff noise. We never did figure out what it was, but he made 3 trips to Moab and ran the Rubicon along with numerous local trails with no issues and it still clacked when he sold it.
 

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Discussion Starter #29
Alright. I may have found out what the issue is. I got feed up and took the jeep to a driveline specialist to have them diagnose it because I had hit a wall. After a week or so of research and diagnosis on their end they are convinced it is the brake pads, specifically the friction of the pad against the caliper. If you remember, I removed the passenger front caliper to try to rule that possibility out. However, I did not isolate the drivers front caliper (shame on me). Nonetheless, upon their research they have discovered that around this model year it is necessary to put shims on the front brake pads. Apparently this is a known problem around this year model. Attached is the picture of the really expensive shims that will hopefully fix the issue. I say really expensive due to the total cost of the hubs, u-joints, etc. At least I have a new front end now! So far the jeep is driving great and no issues. Hopefully, in a few days I can confirm this!
 

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Discussion Starter #32
Well I think we can finally close the case on this one. After a week or so of driving with no issues... the culprit was the brake pads. Adding shims to them has stopped the issue. Hopefully the thread will help the guy or gal who suffers the same ailment in the years to come. Thanks to everyone who has offered help and advice!
 
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