Thank you guys for the replies.
I'm going to give my best attempt to answer everything.
I've only had the TJ for 6 months. Bought it in fairly rough mechanical shape, and have spent my time with it getting everything back "nice".
Blown tie rods, busted control arms, loose track bar, grinding transmission, etc. It was rough.
So the only "baseline" I have to judge from is that hunk of 45mph deathtrap on the day I bought it.
I've spent a LOT of money building it up how I want it (something I can hit the mountain gulches with, but also drive 6 hours away if I want)
I've pretty much been troubleshooting/fixing things as I find them, and there's not much underneath that I HAVEN'T checked.
All modifications were done in the last 6 months, and Steering issue has been part of that for the entire time.
(Hence why I point fingers at Ball-Joints and/or Steering box. They're the only steering components I have checked, but not replaced)
Toe was measured using 3' flat-stock on the rotor surface (actually followed
@Jerry Bransford 's alignment thread for this) , as well as verified on an alignment rack.
I am entertaining the idea of the steering box being the culprit. When I first got the TJ, one of the first things I messed with was the adjustment screw, because I had about 3" of play in the steering wheel. Return to Center was NOT okay before the adjustment, so I disregarded the adjustment as causing the issue. Although I am willing to admit, I could be 100% incorrect, or maybe the steering box was already too far gone?
It's really an odd issue, and it's more than irritating because I am willing to bet it's something uber simple.
I'll throw the TJ on some stands tonight, yank the tie rod off, and see if the BJ's are binding.
Also, If I disconnect Pitman arm and rotate the arm by hand, should the steering box feel relatively loose? or would it have some resistance?
I guess what I'm asking is how do I "check" the steering box for abnormal binding?
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@Jerry Bransford
I LOVE my ramps. They are the number 2 thing I've ever bought for the garage. (number 1 being my toolbox. lol)
I've had them for years, across multiple vehicles.
They're the Schwaben 67" 2-Piece Ramps. $500...
ALSO TO NOTE, They are one of the only ramps I've seen that are backed with a LIFETIME WARRANTY.
(Not sure how to post links yet, but hopefully this works?)
https://www.ecstuning.com/b-schwabe...pc-67-low-profile-car-ramp-pair/006160sch01a/
I was a Vinyl Wrap Installer, so mine are the Low Profile ramps for getting some of the Sports cars onto.
But for the TJ's or "normal" vehicles, don't waste your money on the Low-Profile ones.
They make a 40" pair for only $200.
https://www.ecstuning.com/b-schwaben-by-race-ramps-parts/40-car-ramp-pair/006140sch01a/
I think they're advertised as weighing only 15lb each for the 2-piece designs, or like 5lb? for the 1-piece ramps.
They're made out of EPS Foam, and coated with some type of hard-rubberized "bedliner" type coating.
I prefer them over metal/plastic ramps, because of the build-materials.
I don't have to worry about being underneath cracked welds, or shitty designs/materials.
I never have an issue with them sliding, and not once have I felt unsafe underneath them.
Have used them for years and they still clean up like brand new.
I would buy another set right now without hesitation.