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i just had similiar zip tie noise, turned out to be the drivers side unit bearing. The noise was rotational like yours and very annoying. When i took the old one off it seemed fine, no play, spun ok, looked alright. Let us know what it turns out to be...
looks like a lotta fun, hope it has some subframe reinforcement. It would look even better if you lose those sideview mirrors and go stock or 97 +. Oh the tickets i would have with this thing ...
if only i could figure out how to post pics, i would show you how mine is all smashed in from a rock that was hidden in a large puddle. The skid is caved in pretty good, but i'd rather that than my steering linkage. Working on the jeep is more of a pain with it there, but for me it stays!
do you still have drums brakes? i bet it has to do with them if you do. If you haven't already do the zj swap and have one less thing to screw with. I have already taken the drums off more than once to see the brakes and springs just fall out, and that's not only on jeeps. Drum brakes suck
do the wiring upgrade, buy the new HYPER bulbs from rallylights.com for use in the autopal e4 housings they are AWESOME!! the lights won't be as good if you don't upgrade the wiring i used 12 ga. make sure you use relays. The blue bulbs that come with the atuopal e4 housings off of ebay SUCK...
the transfer case rebiuld kit is available through chryslerpartsdirect.com, for 16.00 that's all it cost me and no more rattles, searching for it on the site is a pita but just call them up and they get ya everything you need hope this will help
don't be turned away by having to enlarge the zj backing plate, it's such a small amount it takes maybe two minutes do both plates with a die grinder and the zj parts are more readily available or at least around here easier to find with junkyard plates and caliper brackets, new rotors,pads,oil...
well i decided that yesterday would be as good a day as any to do my zj disk conversion, and since i had everything apart i would change the outer seals. The whole job was easy and went great and then all of a sudden the brakes started to suck!! i go back home to check things out out find the...
it's the oxygen sensor, i had the exact same symptoms in my 97 i changed the o2 sensor and have been trouble free for over 4000 miles...the one before the converter..hope that helps