Huh. Fortuitous that this was brought back up.
Noticed this last time I had the truck out if I was at or near full lock, I'd get a popping type sound from the front end. Don't believe it was specific to 4WD.
I'd also noticed in the past that my front wheels sure seem to be able to turn at a VERY sharp angle, but I haven't seen any specs for what max supposedly is. I can't imagine its for some reason out of the norm, but compared to the IFS trucks, it seems to be able to turn a heck of a lot sharper, even ignoring the benefits of the short wheelbase. Had a lingering thought that was somehow part of the problem, since full lock seems to be the point it makes the noise.
Going to keep my eye on this thread.