Recently purchased a 2000 XJ, 203,000 miles. Had my mechanic friend at the Jeep dealer do the following work on it and now I have a rattling sound coming from the front end somewhere. It is more prominent and consistent when the Jeep is cold from about 20mph to 40 mph, after driving 10 miles or so it is less prominent and more sporadic. I will be cruising at 55 and it will occasionally start rattling really loud for 5 seconds then gone. It is not present at idle or very low speeds. This is what was done to it....

Front/rear diffs drained, resealed and filled. No metal present
Transfercase drained, refilled. No metal present.
Oil change done. No metal present
All tires balanced reinstalled.
Front end alignment done.
2" budget boost installed, cups in front, drop shackles in back.

Rattle was not present before all this done.

Jeep recently had the trans mount, and motor mounts changed out so they are fairly new. Also checked the clearance of the sway bar mounts to the shocks, and that appears fine.

I did trim the tailpipe back because it was rubbing the drop shackle. Was hoping that was it, but nope. Runs, shifts perfectly. Retried all 4x4 modes.. all working as it should. Any thoughts would be most appreciated. I will be taking it back to his shop on Saturday to put it up on the rack and inspect.

 

Check all nuts and bolts.

How old are the shocks?

 

Had it up on the rack again. Found the transfer case mount bolts about to fall out. Tightened those down. No difference. Also found that the exhaust down pipe from the manifold is practically rubbing the oil pan. Thinking this might be the source. Anybody run into those? Everything else appears tight. Shocks not sure how old. I have a set of Jk Rubi shocks I plan on installing here soon as well.

 

Check the exhaust and it's hanger where it passes over the crossmember.

 

I have the same rattling, exhaust is rubbing against skid plate. Rattling comes and goes.

 

I did. It is a son of a ***** to listen to that manifold. I cut my center crossmember mount off the exhaust and moved the rear hanger over to get it off the pan.

 

Well I will let you know if this is my issue. I will be dropping the oil pan as well to do the rear main seal and front seal at the same time. Keep ya posted