Hello everyone, I will try to explain this the best I can. My 04 Wrangler has developed a clunking noise which I can feel under the gas pedal. The problem is the noise is only appears in the afternoon and when the Jeep is in motion you can feel it even on mlid pitches in the road, it is always there and feels like something loose.
My Mechanic checked it twice thoroughly and said nothing is wrong, the transmission and motor mounts, clutch and suspension are all fine.
And besides I figure if it was any of those than it would do it all the time, it's almost like when it has been driven for awhile and it is hot when it occurs.
I have resolved myself to wait until something breaks than we will know, it is the mystery clunking noise. Today had me scratching my head even more over this since it did not do it all.
Thanks.

Did you check you exhaust mounts? mine are loose and they clunk a little.

The exhaust is tight, I even crawled underneath and grabbed hold of it and there is no play. I also thought the exhaust was loose because the clunk would also occur when accelerating form a dead stop, it felt like the exhaust was hitting the floorboards.

did you check u joints?

My Mechanic claims he checked everything thouroughly so I would assume yes, but we all know what assume means. My problem is when I am driving down a long stretch of road, I can feel it under my feet all the time like something came loose and is banging on the floor boards. So I doubt it is the U-Joints but I am no Mechanic, I only know so much.
The only options I have is to take it to a Jeep Specialist or wait until something breaks.
But bringing into a garage and tying it up looking for something that nobody can find can be costly, which I have done twice so I am stumped.

check the tranfer case shift lever bracket that bolts to the dvrs side floorboard under the jeep you probley lost the bearing for the shift pin thats what happened to me same noise and all i even felt it sometimes.it does it sometimes and sometimes not so that may be your problem

Thanks for the responses, I am going to drop it off to my Mechanic this week and have him check to make sure the bearing is not missing.

its easy to see dont pay for it to be looked at im telling you just grab that pin and shake it and you found your prob very easy to change out for anyone i chased this same prob for 4 weeks befor i figured out what it was

Ok, I did call my Mechanic and he said he checked that and the bushing was fine, I will take your advice and when the weather breaks I will get back underneath and check it myself. Chasing this noise starts to work on your sanity. Thanks

i will try to post pic of what im talking about befor i leave in 30 mins

looking up to drivers side floor

and you can see the missing bearing/grommet.
and befor all say something about the underside of my jeep being dirty i drove through some paint that some j/a poured in the wash after the rains at least i use it

that should be your problem right there just grab that pin and wiggle and jiggle.or have someone else do it and you sit in the jeep to feel it. i bet it will be the same feeling in the floorboard as what you describe. at least that was my problem gl

and if so the parts kit for that is just over $20 for a local dodge/jeep dealer

You guys are great, thanks for pics and help! I located the lever and it has no play and I don't see anything missing. So maybe for the cheap money I will just replace it and see what happens.

Well I went to the jeep dealership and picked up the part, my Mechanic is pretty flexible with me so I am going to let him put it in.
The noise was there all day today and when I put my hand against the transfer case I can feel the clunking against it, so I am pretty convinced that is the problem now.
What did hurt though was the price for the part, how does $82 sound?

Way to much I think I might of found a different dealer.

i was quoted $12.85...did he have a gun pointed at you when he sold you that part..wow
did you get the whole bracket or just the bearing

That was my next question I bet that was the entire bracket.

I bought the whole bracket but I am looking at this on a positive note. I found the noise and it could have been worse, it could have been the transfer case. The pics AZ helped me out, so thank you again for that.

no prob trust me i got rattles shakes vibrations on mine all the time so i tend to know a thing or two about pos jeeps that get abused. glad the pics helped and happy wheeling

The job is done, and I am glad I replaced the whole bracket. The rubber grommets on the bolts were all dry rotted and the bearing was still in place but it was cracked.

holy hell.. this has been driving me absolutely nuts. I have a clunking in the drivers side floor board as well. It doesn't happen all the time, often times when I go over a mild pitch in the road or sometimes on bumps. I usually feel it in the my feet vs. actually hearing it, but I couldn't find anything wrong after getting it up on the rack. I'll take another look at this and see if thats the problem.

AZlenny, I didn't see the pic of the bracket. Can you post it on the thread? Or did I miss it!