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Discussion Starter · #1 ·
Wondering if anyone has had this issue or maybe sounds like something someone may have an idea on.

Been chasing this rattle since I have had this Jeep. Every crack in the road, pothole, etc, it rattles. This is a thin tin, metal rattle sound. Best way to describe it is take an old metal coffee can, throw a couple 16d nails in it and shake it. It sounds like it is coming from the heater box under the passenger side dash. I have had the wife in there trying to isolate the sound, nothing external is loose. I have gone through the battery box all the way down the firewall. Everything is tight, no rattles.

Up behind the dash, I pulled out a bunch of junk. Old pens, ticket stubs, etc that had fallen in that little channel between the dash and the windshield. I see there are 2 big holes that I assume are for the window defroster. I am wondering if some of his junk may have fallen into those holes (they are big wide open holes) and landed down in the heater box??? Can I remove that vent door of the heater box to gain access inside the box?

Thank you all in advance!
 

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My vent door rattles just like you hear. The foam is gone off the flap or door and it bangs around when in the vent? position. Another thing was the cables for the heat system. IIRC one was laying on top of the heater box and rattling around as well. I hate rattles and squeeks...arggg.
 

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My vent door rattles just like you hear. The foam is gone off the flap or door and it bangs around when in the vent? position. Another thing was the cables for the heat system. IIRC one was laying on top of the heater box and rattling around as well. I hate rattles and squeeks...arggg.
 

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Discussion Starter · #4 ·
Thank you 8th! I will check cables on top of the box. My noise happens regardless of where my vent/heat settings are set. I will double check both though as well. It is strange though that it sound like a hollow tin sound and the heater box is all plastic. That is what had me thinking maybe the PO dropped something metallic in there. I even pulled out an old cell phone li/ion battery from between the space in back of the dash and windshield cowl. HA! Who knows what other crap they threw up there.
 

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Before you pull the heater box, look elsewhere. I had a random clunk when accelerating and decelerating. Not too often, but enough to be real annoying. I searched and searched. It was beginning to drive me batty. One day I opened mu glove box. I keep a flashlight in there, wrapped in a shop rag. I must have used the shop rag for something and didn't put it back. My noise was the flashlight rolling around in the glove box.

For me, rattles and clunks are evil. They hide sounds that might be something getting ready to fail. I'd pull the heater box if I couldn't find the noise elsewhere.
It's a pain to pull, but no matter, I'd have to get rid of the rattle.
Most likely it's something the PO allowed to fall down inside. If it's your vent door, one poster replaced his worn out vent door foam with a mouse pad from his desk. I wish I'd thought of that when I had my heater box out. Mine doesn't rattle, but my foam is shot.

Good Luck, L.M.
 

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'89 YJ 4.2 with MC-2150 Carb & HEI, 2-1/2" Ex. AX-15, NP231 SYE, Adams shafts, F&R ARB, 3
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A few things I've found.

Aftermarket radio install?, something not secured in the back
Defroster vent inside heater box not connected
Hood prop rod not locked and bouncing around
 

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Discussion Starter · #8 ·
A few things I've found.

Aftermarket radio install?, something not secured in the back
Defroster vent inside heater box not connected
Hood prop rod not locked and bouncing around
Yup, I have gone over everything under the hood, including my Jack assembly. I have added small pieces of rubber to anything at all that might rattle. That sound I am hearing is similar to an aftermarket radio box rattling around but not the case on mine.

It looks like there are a handful of screws around the vent door, anyone removed that to gain access to the inside?
 

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I once had the rattle that you describe, drove me crazy. The cause: slack/excessive clearance in the hood hinges. The diagnoses: wedge a rubber hose or a rag between hood and cowl and test drive. The repair: installed a formable rubber sealer (like those found around a boat compartment opening) along the bottom/back edge of the hood. This creates just enough tension/interference to keep the hood hinges from rattling. Good Luck..... let us know what you find.
 

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Discussion Starter · #10 ·
I once had the rattle that you describe, drove me crazy. The cause: slack/excessive clearance in the hood hinges. The diagnoses: wedge a rubber hose or a rag between hood and cowl and test drive. The repair: installed a formable rubber sealer (like those found around a boat compartment opening) along the bottom/back edge of the hood. This creates just enough tension/interference to keep the hood hinges from rattling. Good Luck..... let us know what you find.
Thanks, I will check this out!
 

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Check the rubber bumpers between the hood and fenders...
Also check that the dash speakers aren't loose.
 

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I'd forgotten about the hood hinges. I remember other posters mentioning how they rattle.
A new gasket between the hood and cowl panel seems to be the cure.

Good Luck, L.M.
 

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Cat heat shield?

The hardest rattle I ever had to track down, that sounded like a 2x4 bouncing around in a truck bed, turned out to be ice that had formed between the inner and outer fender that was bouncing around inside it.
 
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