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Mantrans 04-25-2013 10:36 AM

2002 Sahara Rattle
New Member First Time Posting. I have a 2002 Sahara Wrangler 5 speed that has a "rattle" in the drive train. The Jeep is completely original with 45,000 miles on it. Never been in snow or taken off road. It's probably been in 4wd twice. (wife's summer ride). I own a garage and have experienced mechanics but we can figure this one out. Under load there is no noise. Once you let off the throttle the rattle starts. You can put it in neutral, clutch in or out, engine running or off and it will continue to rattle until you coast to a stop. There is minor play in the front yoke of rear drive shaft. I bought a new yoke and two new u joints from Chrysler. Still does it. I changed front and rear end fluids checking all gears while in there. Still does it. I put it on one of my lifts but it wouldn't do it with no load on the tires. I removed rear drive shaft and drove it and the noise stopped. I don't think by doing that tells me it's the rear end I think it just stopped the transfer of noise through the drive train.
Any ideas would be greatly appreciated from the Jeep Experts. Thanks!!

808DanK 02-05-2016 02:49 PM

I think I have the same issue. Does the rattle sound kinda like thin empty tin cans banging into each other under the car? I've gone down the same path as you.

Now I'm thinking its an exhaust issue? Grabbing at straws at this point.

tworley 02-05-2016 03:22 PM

Check your cats. That sounds like tin cans. The material eventually wears out causing the sound. Mine went bad at 80k miles

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