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I would think it's just your crossmember. Can you visually see it bent upwards?

It's either that....or......your jeep is folding like a taco. :rotfl2:

I am betting it's the t-case going to explode.........:D

Nah it's probably just it rubbing against the tunnel. Lower it down and see what that does. Make sure the motor mounts are good, never...

Best thing to do is just pop it open and see what's going on inside. If i were you, i'd just go spend $$ on a 231 and put the 242 aside as a spare like you said. The 231's can be had for pretty cheap...