1999 TJ has a fluttering / clacking sound in drive and sometimes in park

I can't see the video clearly but at least you've got it lined up.
There may be a bigger hole above the bolt hole in flex plate that you can use to pull converter forward.
Between the flex plate ring gear and the transmission housing there should be enough room to get a thin piece of steel or screwdriver to help pull the torque converter forward as well. It shouldn't take much if you can lift the torque converter near bottom center.
 
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I can't see the video clearly but at least you've got it lined up.
There may be a bigger hole above the bolt hole in flex plate that you can use to pull converter forward.
Between the flex plate ring gear and the transmission housing there should be enough room to get a thin piece of steel or screwdriver to help pull the torque converter forward as well. It shouldn't take much if you can lift the torque converter near bottom center.

Flyinfish, using a long, thin metal ruler, I was able to slide it in under the gear teeth and push the torque converter closer - THANKS!
I'm on my final bolt, but it's not catching on the TC hole threads.

My question: Is there certain alignment that must be used with the holes on the flextplate and the holes of the TC?
 
Flyinfish, using a long, thin metal ruler, I was able to slide it in under the gear teeth and push the torque converter closer - THANKS!
I'm on my final bolt, but it's not catching on the TC hole threads.

My question: Is there certain alignment that must be used with the holes on the flextplate and the holes of the TC?

No, the bolts should screw in without any issue. Can you see the threads in the torque converter hole and do they look ok and not damaged?
 
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No, the bolts should screw in without any issue. Can you see the threads in the torque converter hole and do they look ok and not damaged?

Blurry with my phone. I hope they're not damaged. I'm wondering if I tighten some more the other three, it might help?
 
Blurry with my phone. I hope they're not damaged. I'm wondering if I tighten some more the other three, it might help?

If you have three of the four bolts in then you can pull it up so it touching the flexplate to get the final bolt in. If you can't thread the last bolt in you need to get a mirror or your phone to look at the threads closely to make sure they aren't messed up.
 
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If you have three of the four bolts in then you can pull it up so it touching the flexplate to get the final bolt in. If you can't thread the last bolt in you need to get a mirror or your phone to look at the threads closely to make sure they aren't messed up.

I think it's stripped. The bolt becomes 'tilted' and tightening does nothing. darn. Would I need to replace the TC? Run with only three bolts?
 
Brilliant mirror idea. The threads look okay, i guess. the flexplate hole has worn a bit oblong though;

bolt hole.jpg
 
Brilliant mirror idea. The threads look okay, i guess. the flexplate hole has worn a bit oblong though;

View attachment 339061

That's exactly what I was worried about. You can see the oblong hole where the bolt has been beating against the flex plate. It appears the threads took a beating as well.
I wouldn't give up yet. I'd get a thread chasing tap and carefully chase those threads so it can accept a bolt again.
Have you done any tapping before? If you have then great, If not you may ask a friend who has. You need to hold the thread chasing tap as perpendicular to the flexplate as possible applying pressure and some type of tapping fluid. Take your time!
 
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That's exactly what I was worried about. You can see the oblong hole where the bolt has been beating against the flex plate. It appears the threads took a beating as well.
I wouldn't give up yet. I'd get a thread chasing tap and carefully chase those threads so it can accept a bolt again.
Have you done any tapping before? If you have then great, If not you may ask a friend who has. You need to hold the thread chasing tap as perpendicular to the flexplate as possible applying pressure and some type of tapping fluid. Take your time!

Okay, that'll be my next course of action. Never heard of the procedure nor know anyone who has done it, but will figure on doing it myself...carefully. Thank you so much
 
I'll find the size and thread pitch of the converter hole threads so you can get the correct size thread chasing tap.

It's important that you do this right because the next step is maybe an insert and after that it's pull the transmission.
 
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Okay, that'll be my next course of action. Never heard of the procedure nor know anyone who has done it, but will figure on doing it myself...carefully. Thank you so much

Since this is not a job to learn on, let's try to clean up the threads so there's no dirt or grease in the threads. Spraying the threads with brake clean would work well but use whatever you have to clean them up so we can evaluate how bad the thread damage is. You may just have damage to the lead edge of the first thread and may be able to fix it enough to get the bolt started. After you get it cleaned up, retake another picture like the previous one.
 
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The more I look at the hole in the picture the more I think the flexplate needs to be replaced. The hole in the flexplate looks bigger than the bolt diameter by a pretty good margin. The surface of the flexplate around the holes have been worn badly as you can see the recessed area it created. Another possibility is a crack on the flexplate, but you wouldn't be able to see one because the surface has grease on it. Lastly, the other bolt holes are similar I'm sure.
The flexplate is actually an important part that works together with the torque converter and as the name flexplate implies, flexing is exactly what it does.

I'd say if you can end up getting the last bolt in then this should only serve to be a temporary fix and you should have the flexplate replaced when possible. At that time it also be a good idea to replace the rear main seal, front pump seal and possibly the torque converter.

I'd hate for you to have the flexplate break and cause bigger issues. I'm not sure how long you noticed the noise and continued to drive it before finding out what it was but it appears a little time elapsed.
 
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Since this is not a job to learn on, let's try to clean up the threads so there's no dirt or grease in the threads. Spraying the threads with brake clean would work well but use whatever you have to clean them up so we can evaluate how bad the thread damage is. You may just have damage to the lead edge of the first thread and may be able to fix it enough to get the bolt started. After you get it cleaned up, retake another picture like the previous one.

Cleaned it up and took images and a video. I'm concerned if there's enough clearance to get a thread chase tool in there anyway.
wFof1Y1.jpg
 
The more I look at the hole in the picture the more I think the flexplate needs to be replaced. The hole in the flexplate looks bigger than the bolt diameter by a pretty good margin. The surface of the flexplate around the holes have been worn badly as you can see the recessed area it created. Another possibility is a crack on the flexplate, but you wouldn't be able to see one because the surface has grease on it. Lastly, the other bolt holes are similar I'm sure.
The flexplate is actually an important part that works together with the torque converter and as the name flexplate implies, flexing is exactly what it does.

I'd say if you can end up getting the last bolt in then this should only serve to be a temporary fix and you should have the flexplate replaced when possible. At that time it also be a good idea to replace the rear main seal, front pump seal and possibly the torque converter.

I'd hate for you to have the flexplate break and cause bigger issues. I'm not sure how long you noticed the noise and continued to drive it before finding out what it was but it appears a little time elapsed.

Agreed the more I look at it, too! This is my daughter's vehicle for college. When she returned home for the summer, the sound began on the freeway. So, some time has elapsed. Okay. She, my wife and I have things to consider in how to proceed with the repairs. I appreciate your time and insight.
 
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Agreed the more I look at it, too! This is my daughter's vehicle for college. When she returned home for the summer, the sound began on the freeway. So, some time has elapsed. Okay. She, my wife and I have things to consider in how to proceed with the repairs. I appreciate your time and insight.

No doubt in that last picture the material around the holes is weakened and widened and If it isn't cracked yet, it will. You can see where the bolt was hitting the flexplate that it's thicker than other areas around the bolt hole.

It's a good lesson on noises that crop up, which once you started looking, you did a good job finding the source of the noise.
Hopefully you have some shops close by that can give you a reasonable rate to get it fixed. I was happy to help you where I could.
 
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No doubt in that last picture the material around the holes is weakened and widened and If it isn't cracked yet, it will. You can see where the bolt was hitting the flexplate that it's thicker than other areas around the bolt hole.

It's a good lesson on noises that crop up, which once you started looking, you did a good job finding the source of the noise.
Hopefully you have some shops close by that can give you a reasonable rate to get it fixed. I was happy to help you where I could.
Still considering our options. The repairs will most likely be pricey and at least half of what we paid for the vehicle. Not sure what we want to do. I may just try to chase the thread. At this point, why not...? I think I'll need to drop the oil pan to have a straight approach to the hole. If I screw it up then I should consider repairing myself (I'd need to purchase or borrow a transmission jack, I think), but I just don't think we'll have the fortitude to pay for repairs. Thanks again
 
Finally was approved on the FB Jeep support. Some suggestions included welding a bolt, helicoil , and running with one less bolt (but this suggestion seem to imply I had 5 bolts and running with four wouldn't be too off-balanced?!?)

We may just do a temp fix and have our youngest son drive it around town and passing my wife's car onto our daughter for college in the fall.
 
I definitely wouldn't run it without all the bolts installed. I'm not 100% sure but believe the bolts are 5/16"-20 in the torque converter. You can take whatever path you'd like but to fix it properly you should replace the flexplate.
 
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I definitely wouldn't run it without all the bolts installed. I'm not 100% sure but believe the bolts are 5/16"-20 in the torque converter. You can take whatever path you'd like but to fix it properly you should replace the flexplate.

What are your thoughts on a helicoil?
 
What are your thoughts on a helicoil?
There's no reason to go to a helicoil or other style inserts because there's plenty of good threads remaining in the converter. You can probably chase those entry threads up and be good to go. A helicoil requires drilling out the threads to a given size, tapping and then installing new insert to original bolt size. The converter hole is blind and shallow which complicates the process if an insert was used.
 
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