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Unread 04-28-2014, 04:37 PM   #1
samlancashire
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Metallic Rattling Noise- worse after installing new muffler!

Hey guys,

I drive a '03 TJ with a 2" budget boost. Muffler was getting bad, making all kinds of noises. Replaced it last weekend with a Dynomax SuperTurbo. The heatshield was falling down a bit so I bolted it back up.

One of the noises that I had before that I assumed was the heatshield has become a bit louder and is happening more frequently. It sounds like pieces of metal rolling around inside a tin can. Happens between 1700-2000rpm, whether the wheels are turning or not.

One thing I noticed after my newb muffler install is that the tailpipe is almost touching the rear track bar. I tried to knock the tailpipe against the trackbar with my hand but it was pretty sturdy and I can't see this as being the cause of the noise. Am I wrong? What else could this noise come from?

One more thing that might be pertinent:
Halfway through the muffler install I realized I bought a wrong sized fitting. Didn't feel like going back to Canadian Tire so I left the project over night. I had the skid plate off and was supporting my transmission with a floor jack.
The piece of **** jack drooped over night and let the tranny hang by itself. Nothing seemed damaged and the jeep drives just fine.

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Unread 04-28-2014, 04:42 PM   #2
Jeffro06
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Heat shield on catalytic converter? Or the converter itself?
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Unread 04-29-2014, 04:16 PM   #3
samlancashire
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Heat shield is pinned up fine everywhere. Tried banging on the cat with a rubber mallet and didn't sound like anything was loose inside.

Edit: I've also checked transfer case fluid since my original post and it is good.
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Unread 04-29-2014, 04:33 PM   #4
TheBoogieman
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When my cat went bad,it only rattled when the Jeep was running.Banging on it didn't produce any noise.It got progressively worse and louder.
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Unread 04-29-2014, 05:48 PM   #5
samlancashire
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Quote:
Originally Posted by TheBoogieman View Post
When my cat went bad,it only rattled when the Jeep was running.Banging on it didn't produce any noise.It got progressively worse and louder.
Good to know. Won't cross cat off the list yet.

Broken bits inside the cat is also a good explanation for the noise getting worse after replacing my muffler. I used a sawzall to cut the old muffler out and it definitely shook things up a bit.
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Unread 04-29-2014, 06:03 PM   #6
joek81d
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Any contact with your rear shock? Check your exhaust manifold bolts for tightness as well.
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Unread 04-29-2014, 07:12 PM   #7
BYuen
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Get someone to help and rev the engine to make the noise while you go under the jeep and locate it. Sounds like it could be the cat.
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Unread 04-30-2014, 10:08 AM   #8
samlancashire
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Quote:
Any contact with your rear shock? Check your exhaust manifold bolts for tightness as well.
Will try to get underneath it this weekend and have a look at manifold/flange bolts. Rain in the forecast for next 7 days
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Unread 05-03-2014, 04:57 PM   #9
samlancashire
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Update on this: I had a chance to get underneath the jeep today. I'm 99.9% sure it is the two mini cats up at the manifold. They each have a thin layer of metal around them which I guess is a type of a heat shield that is rusting and falling off. If anyone knows what I'm talking about can I just rip these shields off?
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Unread 05-03-2014, 07:35 PM   #10
BYuen
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Quote:
Originally Posted by samlancashire View Post
Update on this: I had a chance to get underneath the jeep today. I'm 99.9% sure it is the two mini cats up at the manifold. They each have a thin layer of metal around them which I guess is a type of a heat shield that is rusting and falling off. If anyone knows what I'm talking about can I just rip these shields off?
If it is just the shields, you can remove them. My replacement mini cats and y-pipe did not come with the oem style shields. Been fine for 70k miles now...
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Unread 05-11-2014, 04:03 PM   #11
samlancashire
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Removed one of the shields. Noise went away but I took it up the road and back (~10km) and my engine light came on- P0122 Throttle Position Sensor A Circuit Low Input.
I felt my hand around the two cats after my trip, and the air is quite a bit warmer outside the one without the shield now, and there are fuel lines close by that felt pretty hot (I could keep my hand on them but they were quite hot). This OBD code seems totally unrelated, but is it possiblly to do with warm fuel...?
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Unread 05-11-2014, 07:34 PM   #12
BYuen
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Just a coincidence. The TPS is in the throttle body and is not directly exposed to fuel. Also, anything near the cats even with the shield will warm up pretty hot. They'll normally be anywhere from 500-800 degrees.
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Unread 05-12-2014, 05:49 PM   #13
samlancashire
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Thanks BYuen. Replaced TPS today, problem solved. Totally coincidental.

Edit: $72 for what I think is just a potentiometer? Damn!
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Unread 05-12-2014, 07:00 PM   #14
BYuen
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Haha I'm assuming you got the Mopar part? That's good though, I wouldn't trust aftermarket when it comes to parts like that. The markup is high. Usually you can find it cheaper online. Only problem is, when you need it you often need it now and can't wait for it to be shipped. Also, if you get to know the guys well enough at the parts counter on a first name basis, sometimes they'll give you a discount.
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Unread 05-13-2014, 06:37 PM   #15
samlancashire
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Yeah, Mopar. I'm also in Canada, car parts and certain things just seem to be more expensive! Honestly I could've ordered one off eBay for a quarter of the price. The engine light just bothers the hell out of me.
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