andyblack
Registered Loser
popping sounds cured
I just wanted to let everyone know that I found out what was causing the popping sounds and fixed it. It had nothing to do with the XJ steering shaft or box or anything, even thought it sounded like the noise was coming from around the steering box output shaft. It ended up being loose nuts on top of the u-bolts on the driver's side. I guess that since I got the steering working so well and got the pitman arm good and really tight, the forces the steering was able to exert were great enough to move the axle around a lot more on that side and make the nuts loosen up. I tightened them to 140 ft./lbs. (they were only at about 100 ft./lbs.) and the popping sounds went away. Yes!
Now I've only got about four other mystery sounds to track down and silence and then my nerves can finally calm down while I'm driving. 
I just wanted to let everyone know that I found out what was causing the popping sounds and fixed it. It had nothing to do with the XJ steering shaft or box or anything, even thought it sounded like the noise was coming from around the steering box output shaft. It ended up being loose nuts on top of the u-bolts on the driver's side. I guess that since I got the steering working so well and got the pitman arm good and really tight, the forces the steering was able to exert were great enough to move the axle around a lot more on that side and make the nuts loosen up. I tightened them to 140 ft./lbs. (they were only at about 100 ft./lbs.) and the popping sounds went away. Yes!
Now I've only got about four other mystery sounds to track down and silence and then my nerves can finally calm down while I'm driving.